IBS Enterprise Help Centre 8.0Business Suite 2014/2015

Loading data in IBS Manufacturing tables and files

There are a number of tables and files in IBS Manufacturing that need to be initialised before the system can be released for transaction handling in a live environment. Perform this procedure in the order outlined below.

What this document contains:

Tables/Files

Table/File To do
Manufacturing order type table This table is used to control how the order is handled and what kind of reporting should be performed. At least one manufacturing order must exist for the company installation. The manufacturing default value for a panel can be set-up in the Manufacturing application control file and in the IBS user profile table. Complete the following fields:

    Backflush material when deliver to stock
    Indicate if automatic back flush of remaining non-withdrawn material, according to the material structure on the manufacturing order, should be made at reception of finished products. The condition for a material to be backflushed, is that the material has been coded for this purpose in the item/warehouse file, i.e. the Floor Stock code field has the value for Backflushing item.
    Backflush max as manufacturing order
    Backflush material maximum as manufacturing order is a method to control if backflush should create a material consumption exceeding the amount reserved for the manufacturing. This applies even if the backflush takes place at operation reporting or at delivery to stock. If you set this field to NO, the material will be backflushed according to the produced quantity, irrespective of the quantity reserved for the manufacturing order. If you set this field to YES, the system will backflush up to the ordered quantity, but not more even if the produced quantity is higher. In the latter case, excessive issues will be handled by the function for unplanned material issue.
    Close not started operations at end
    If you set this field to YES, not started (i.e. not reported) operations with status "10" or 20 will be updated automatically when the manufacturing order is reported as completed. Operations that are not started receive time/unit * quantity produced as cost account value, which also applies to the cost control.
    Backflush material at operation reporting
    Indicate if material connected to the operation should be automatically backflushed when reporting operations. If material entries are not connected to an operation, the material will be backflushed at the order's first operation. Prerequisite for material to be automatically backflushed is that the material has been coded for this purpose in the item/warehouse file, i.e. the Floor stock code field has the value for Backflushing item.
    Backflush location/batch items
    Indicates if warehouse location handled, serial number or batch-controlled items may be automatically backflushed when reporting operations, or reception from manufacturing order. If you set this field to YES, a display will be shown at backflush, when operation reporting or reception from manufacturing order is taking place, on this display warehouse location and/or batch identity should be entered. A prerequisite for this function is that the manufacturing order type parameter Backflush material when deliver to stock or Backflush material at operation reporting is set to YES.
    Reception at last operation
    Indicates if delivery to stock will be done for the produced item when reporting the last operation for the manufacturing order.
    Allow reporting without print shopfloor
    Indicates if reporting on a manufacturing order which has not been printed, (i.e. order status 10 (ready)), is allowed.
    Batch clearance
    Indicates if the created manufacturing order should go through an extra confirmation step before it is possible to start the production. If this field is set to YES, created manufacturing order will get order status 05 (not clearance) and must be accepted in the batch clearance function before the order status is 10 (ready).
    Included in WIP
    Indicates if manufacturing order with this order type should be printed on the WIP report.
    Order statistics
    Indicates if the completed manufacturing orders should be stored in the Manufacturing order history file when completed manufacturing orders are reorganised.
    Create lower levels
    Indicates if manufacturing orders for included subassembly items should be created when the parent items manufacturing order are created.
    Disp check lower lvl
    Indicates if disposal check for lower level manufacturing orders should be done. This field can only be set to YES if Create lower levels is set to YES.
    Batch no at creation
    Indicates if the batch number of the produced items should be generated at the creation of the manufacturing order. The generated batch number will be created from the batch mask that is defined for the item in the Item file, Inventory information. If you set this field to NO, a batch number must be manually entered when the manufacturing order is received.
    Direct/delayed pur creation
    This field is only displayed when the Direct pur to m-order field is set to YES in the MFG control file. Indicate if a purchase order should be created directly after the manufacturing order has been created or delayed creation, (i.e. manually or through a batch function). Valid codes are:
    Code Description
    1 Direct creation
    2 Delayed creation
    3 No purchase order
    Issue at pur receipt
    This field is only displayed when the Direct pur to m-order field is set to YES in the MFG control file. Set this field to YES if the material should be issued to the manufacturing order when the connected purchase order reception is made. Set this field to NO if the issue should be made within the normal manufacturing order reporting routine.
    Purchase order type
    This field is only displayed when the Direct pur to m-order field is set to YES in the MFG control file and is a mandatory entry when the Direct/delayed pur creation field is defined as 1 or 2. Enter a purchase order type that is used to create a purchase order for components defined with direct delivery. The purchase order type must be defined with update stock on-hand and transit delivery.
    Print oper card at
    Enter a code indicating from where the operation card will be printed. Valid codes are:
    Code Description
    1 The operation card will be printed when shop floor documents are ordered.
    2 The operation card will be printed individually from the detail planning module.
    Print pallet labels
    Indicate if pallet labels should be printed when the shop floor documents are printed. This field is only displayed when IBS Warehouse Management is installed and activated in the company in which you are working. Note: Pallet labels are only printed for items that are defined with automatic pallet creation on item warehouse level.
    BtB order status
    Enter a code defining what status the manufacturing orders should receive when they are created from BtB orders (= manufacturing order linked to sales or project order line). Valid codes are:
    Code Description
    1 BtB manufacturing orders will receive status 00 (preliminary).
    2 BtB manufacturing orders will receive status 05 (batch clearance) if the Batch clearance field is set to YES in the Manufacturing order type table or if the Order allocation field is set to YES in the Item file on one or more components. In other cases, the status will be 10 (ready).
    3 BtB manufacturing orders will receive status 00 (preliminary) if the manufacturing order start date is within the production time of the item. If the manufacturing order start date is outside the production time of the item, the status will be set according to the same rules as code 2.
Group order type The group order type is connected to every manufacturing group order and controls the following:

  • If the group order should be connected to the manufacturing header or operations.
  • If the manufacturing orders or operations should be reported from the manufacturing group order.
  • If there should be a restriction to the number of orders added to the group order. The restriction/limit can be based on either order quantity or operation time.
  • If a consolidated order should be created in IBS Time. Note: Application MFO must be active.
    Report on group
    Indicate if the manufacturing orders or operations should be reported from the manufacturing group order.
    Used from
    Enter a code defining if the group order type should be used when a group order is created from manufacturing order header (1) or from operations (2).
    Set group on oper
    This field is only relevant if the Used from field is set to 1 (header). Indicate if the group order number should be set on all operations belonging to the manufacturing order that is connected to the group order. If you set this field to YES, the group order number will be printed on the operation card. Note: The group order number that is set on the operations can be used as a selection value in, for example, IBS Planner View.
    Limit type
    The limit is used to control and calculate the remaining capacity of the manufacturing group order. You can restrain the number of orders added to the group order based on order quantity or operation time. Enter a code indicating the limit type to be used for this manufacturing group order. The following codes are valid:
    Code Description
    0 No limit
    1 Limit on order quantity with stop
    2 Limit on planned workload time with stop
    3 Limit on order quantity with warning
    4 Limit on planned workload time with stop
    Limit
    The limit is used to control and calculate the remaining capacity of the manufacturing group order. You can restrain the number of orders added to the group order based on order quantity or workload time. The limit is set up according to the limit type. If the limit type is 0 (no limit) this field should be left blank. In all other cases the field is mandatory. Enter a value indicating the limit for the manufacturing group order. Depending on the limit type, the value can either refer to order quantity or workload time.
    Create group order in TIME
    This field is only displayed when IBS Time is installed and activated. Indicate if a group order should be created in TIME. If you set this field to YES, the group order will be created in IBS Time when the group order in IBS Manufacturing is locked. YES is only allowed when the Report on group field is set to NO.
    Run priority
    This field is optional. Enter the run priority for this group order. Valid values range from 0 through 99, where 99 is the highest priority. Note: The run priority entered in this field overrides the value entered on the operation.
    Run sequence
    This field is optional. Enter the sequence within the run priority for this group order. Valid values range from 01 through 99, where 01 is the highest priority. Note: The run sequence entered in this field overrides the value entered on the operation.
    No of group report
    Enter the number of group order reports to be printed. The report includes all the orders connected to a manufacturing group order.
Cost model The companies cost model must be set-up before starting using the system. The cost model is used for the cost control of manufacturing orders and to calculate:

  • the cost for product costing in basic data
  • the pre-calculated cost on manufacturing order
  • product costing on configured sales order lines
  • product costing for project structures.

You can use the default cost model supplied with the system or define your own. In the set-up of the cost model you choose which costs are to be included in the calculation. You also define when a calculation is to be performed, e.g., on material reporting or operation reporting.

Product costing overhead table The entries in this table are used to define the percentage and/or overhead amount for material overhead that can be used in product costing calculations. To simplify working with material overhead in IBS Manufacturing, the material overheads can be defined per item group, item family or item sector. Examples of material overhead: purchase overhead, goods receiving, receipt control, stores costs, and internal transports. To make the calculation clearer, for instance to be able to differentiate between internal and external costs, IBS Manufacturing includes functions to handle two different material overhead percentage fields and two fields for amount.
Product overhead table The entries in this table are used to define the percentage and/or amount for the end product that can be used in the product costing calculations. To simplify working with product overhead in IBS Manufacturing, the overhead can be defined per item, item group, item family, or item sector. Examples of product overhead: construction cost, warehouse cost.
Base value overhead The entries in this table are used to define overhead costs for internally produced items. To simplify working with base value overhead in IBS Manufacturing, the value can be defined per item group, item family or item sector. Examples of base value overhead: whole or parts of staff costs, development costs, royalty.
Min/Med/Max table This table is used to specify a minimum, medium and maximum level for items having a stock balance. These are the items to be planned using shortage analysis with Planning method set to 5. Levels are specified for a warehouse, and within the warehouse per item group, as well as per sales volume classes A - E. The values given as min/med/max are used when executing Quantity on hand level calculation. The values specified are used as a factor in the calculation:

  • Where "Day Factor" is fetched from the Stock level table's min/med/max values.
  • "X" is a lead-time factor entered when calculating, or stored in Quantity on hand level per item table.
Reason codes This table is used to define reason codes for validation in connection with back reporting from manufacturing order or from project orders. For each reason code a type describing when the code may be used is defined.

System data

The following describes fundamental information and system values necessary to set-up to control how IBS Manufacturing will operate.

In this program you can define the default parameters for creating a new pull planning proposal or updating an existing proposal. The parameters to activate and control the sales and the operation plan functionality are also defined in this program.

Mandatory and important information for the different tables is described. It is important that the information in these tables and files are set-up in the sequence given below, before starting to set up Basic data.

Table/File To do
MFG control file System parameters are used to set up and customize your system. You decide which functions to activate and the way different parts of the system should operate. Complete the following fields:

First panel:

    Variant handling
    This is where you decide if variant handling on structure level should be allowed in the system. This means that you can create alternative preparations for an end product or subassembly item by entering different bill of material and bill of routing for a certain item.
    This function is extremely effective when handling products, which now and then are produced using different material or production methods, but where nevertheless the end product is identical. Set this field to YES if variant handling should be active.
    Warehouse in BOM
    This is where you decide if warehouse should be allowed to be used on structure level in the system. This means that you can create alternative preparations for an end product or subassembly item by entering different bill of material and bill of routing dependent on to what warehouse the end product is produced to. Set this field to YES if warehouse in BOM should be active. Note: It is only allowed to set this to YES when the system value Cost by warehouse is set to YES in DIS control file.
    Log BOM/BOR changes
    Indicate if all changes (add/change/delete) to bill of materials and bill of routings in Basic Data should be logged. If you set this field to YES, you will be able to view and/or print structure information for a specific date in passed time.
    Calendar manufact
    This is where you decide which calendar id should be used to validate dates on manufacturing order header level. Note: At least one calendar must be defined before you start using the system. When a company is generated a default calendar is created called *DFT.
    Days before shortage
    In this field you define number of days before shortage. This is used as an administration time in days between Manufacturing module and Sales orders.
    Critical resrcs only
    This field is only displayed if the IBS Manufacturing finite planning functionality is activated in Work with companies. Set this field to YES if only critical resources should be included when calculating the capacity shortage. Work centres and tools can be defined as critical resources. This value is used when calculating capacity from Sales order, Manufacturing order, MRP, Batch clearance and Pull Planning. It is also used as default value at Material/capacity clearance enquiry. Set this field to NO if capacity clearance should be made for all resources.
    Mtrl shortage check
    Enter a value to be used for disposal check at material clearance. Enter value 1 if disposal date for the component should be the first possible date where needed quantity is available. Enter value 2 if all existing reservations within the lead-time should be taken into consideration when calculating the disposal date for components.
    Cost model
    In this field you decide which cost model should be used as the operational costing model in the system. It is important that the cost model is set up correctly before activating the model. Note: When a company is generated, a default cost model is created called *DFT that can be used as a base to create the company unique cost model.
    Item w c price type
    In this field you decide which work centre price type should be used to control what price field (standard or actual) should be retrieved from the Work centre file during Product costing calculation in Basic data. Valid values are: 1 (standard) and 2 (actual).
    Item cost type pc
    In this field you decide which item cost type should be used in Product costing. The value entered in this field is used as the default value in the Product costing online selection and Product costing batch selection panels. It is also used as a control parameter during update of the item standard cost prices. Valid values are: 1 (average cost), 2 (standard cost) and 3 (FIFO).
    Priority alternative
    When using priority analysis there are four ways for the priority value calculation:
    Code Description
    1 The priority value is calculated from the result of the MRP - run.
    2 Year forecast from item/warehouse or, if year forecast item/warehouse is missing from periodical statistics 12 months back.

    Year forecast from item warehouse file divided with the application control file parameter "number of working days / year". If a year forecast is missing, the value retrieves from inventory periodic statistics 12 months back and divides with the application control file parameter "number of working days / year".
    3 Year forecast from item/warehouse.
    4 Period forecast IC. This value is only valid if IBS Inventory control is activated.

    Priority calc N/D-S
    In the fields under this section you define the formula for calculating priority analysis. The Numerator, Denominator and Subtraction are defined in separate fields using pre-defined variables, constants and valid operators.

    Numerator N
    In this field you define the method for calculating the numerator (N) to be used in the priority value formula N/D-S.
    Denominator D
    In this field you define the method for calculating the denominator (D) to be used in the priority value formula N/D-S.
    Subtraction S
    In this field you define the method for calculating the subtraction (S) to be used in the priority value formula N/D-S.
    Total lead time TLT
    In this field you define the method for calculating the total lead-time to be used to retrieve on order, reservations and forecast within a specific time horizon. The following pre-defined variables are used for calculating the Numerator, Denominator, Subtraction and the Total lead-time (TLT).
    They may be referenced as follows:
    Variable Description
    &01 Quantity on hand
    &02 Total quantity on order (manufacturing + purchase + manual orders)
    &03 Total reservations (sales order + manufacturing order + manual reservations)
    &04 Quantity on order within a total lead time (TLT)
    &05 Reservations within a total lead time (TLT)
    &06 Forecast within a total lead time (TLT)
    &07 Quantity on order per day
    &08 Reservations per day
    &09 Forecast per day
    &10 Highest of daily forecast/reservations
    &11 Lead time
    &12 Order period
    &13 Safety stock days
    &14 Safety stock quantity
    &15 MRP demand within TLT
    &16 MRP demand per day

    Note: The following:

    • Constants must be numeric (0-9) and a decimal sign (,) may be used.
    • Valid operators: +, -, *, /.
    • A maximum of 10 parentheses may be used.

    Second panel:

    M-order number serie
    In this field you define the number series used for automatic numbering of manufacturing orders.
    M-order type
    In this field you define the default Manufacturing order type. This order type is used as a default value when manufacturing order is to be created. This system default value can be overridden if manufacturing order type has been entered on user level.
    Main whs mtrl alloc
    This field is used for handling reservations in requirement calculations, as well as when manufacturing orders are created during release from material requirement planning, priority analysis, and shortage analysis or manually created.

    If the parameter is set to YES, exploded requirements are reserved according to the current item's main warehouse or entered allocation warehouse in the bill of material, if allocation warehouse is set in BOM this value is used before the item's main warehouse. When the parameter is set to YES, components involved in a manufacturing order are also reserved in the current component's main warehouse.

    If the parameter is set to NO, the reservations are created in the "parent item's" warehouse. Components involved in a manufacturing order are reserved in the manufacturing order's delivery warehouse.

    The main warehouse for an item is specified in the item file. The purpose of the code is to make it possible to specify if the material is stored locally, i.e. close to the production site, or centrally.
    M order w c price type
    In this field you define which manufacturing order work centre price type is used to control what price field (standard or actual) that should be retrieved from the Work centre file during manufacturing order pre-calculation and for the back-reporting of manufacturing order operations. Valid values are: 1 (standard) and 2 (actual).
    Auto create M-order
    Indicate if the function for automatic creation of manufacturing orders, depending on the item's item class from the sales order line registration, should be active.
    Workload view
    This is where you define the default value for how the workload enquiry should be presented from the start. The valid codes are: 1 (Week) and 2 (Date).
    Barcode on M-order
    This function is used to indicate whether a barcode should be written on a manufacturing order (operation card and material card). The barcode may be used by a report system handling such codes and to transfer and update information in IBS Manufacturing. Indicate if a barcode should be written on the manufacturing order. If you set this field to YES, you must also indicate the type of barcode to be used (see below).
    Type of barcode
    If a barcode should be printed on manufacturing orders material and operation card, enter what type is to be produced. The valid types are: 1 (code 39), 2 (2/5 int) and 3 (EAN13).
    Re-usable material
    Indicate if the material can be used as re-usable. If you set this field to YES, you will be able to maintain the corresponding field for components in the Bill of material. If you set this field to NO, the field will not be displayed.
    Chk crit order maint
    This field is only displayed if the IBS Manufacturing finite planning functionality is activated in Work with companies. Indicate if the critical work centre should be controlled during the manufacturing order creation, maintenance or re-scheduling. If you set this field to YES, the critical resource will not allow overload on the planned dates. The order will be re-scheduled again based on the critical resource. This means that the critical resource will search for enough free capacity and plan the order from that point.
    Group order no serie
    This field is only displayed if the IBS Manufacturing group order functionality is activated in Work with companies. Enter the number series used for automatic numbering of manufacturing group orders.
    Batch number serie
    This field is optional and is only used for batch-controlled items for which the batch mask set-up uses the attribute %SER%. Enter the number series used to create batch numbers for manufactured items.
    Reporting unit
    Indicate the default reporting unit for operation reporting, material issue and order reception. See Structure unit handling below for more information. Valid codes are: 1 (Stock unit) or 2 (Structure unit).
    Direct pur to m-order
    Indicate if the manufacturing order could create a direct purchase for included materials. If you set this field to YES, you will be able to create a purchase order connected to a manufacturing order material line. In addition, you will be allowed to use fictitious items in the structure. When the manufacturing order is created and the order type is set up to allow direct purchase, a purchase order is created for components (of item class 2 or 4) when no stock is available and for fictitious items.
    Default start time
    This optional field is only displayed if the MPL-TIME (Plan operation by date/time) function is activated in the Function control file. Enter the default start time in the HH:MM format that will be used as a default time when creating manufacturing order with forward scheduling. Note: The default start time cannot be greater than 24, less than 0 and the decimal (minutes) should not be greater than 59.
    Default compl time
    This optional field is only displayed if the MPL-TIME (Plan operation by date/time) function is activated in the Function control file. Enter the completion time in the HH:MM format that will be used as a default time when creating manufacturing order with backward scheduling. Note: The default compl time cannot be greater than 24, less than 0 and the decimal (minutes) should not be greater than 59. Note: The default start time cannot be greater than default compl time.
    Purchase order type
    This is where you define the default purchase order type to be used when purchase order is created from manufacturing order sub-contracting operations. This default can be changed at creation of a purchase order. Note: The order type must be defined without stock updating.
    Purchase order descr type
    This is where you define the default value for which description is to be created on the purchase order line for sub-contract operations. The following codes are valid: 1 (operation description) or (manufacturing order's parent item description).
    Always new pur order
    Indicate if a new purchase order should be created for every sub-contract operation line or if one purchase order should be created for all released sub-contract operations for one supplier.
Batch job handling

(Work with reports/jobs)
A table including all batch programs available within IBS Manufacturing is pre-loaded when the system is installed. For each batch job this table contains defaults for job attributes, such as job queue and out queue, as well as the job parameters.

The Work with reports/jobs, available on all menus, includes functionality to change the defaults for each job as well as submitting jobs.

Changing the job attributes job queue and priority in job queue is restricted to users with the special authority "Job control".

In the table each batch job is connected to a specific "Module". Depending on the menu from which the Work with report/jobs is accessed only related jobs are displayed. A job may be copied to a new version including new settings of the parameter values. By optionally connecting the new version to another "Module" the same job may be accessed from different menus.

It is possible to secure the options to change job defaults and the submit option for individual batch jobs using program security (SECUR). Refer to the Panel help for Work with reports/jobs for more information.
Job parameters

(accessed from Work with report/jobs by using the 2=Change job option)
The job parameters (1 to 29) are unique for every job. On-line batch job documentation is provided to explain each job's parameters. The batch job documentation can be accessed from the "Work with reports/batch job" panel. In jobs where date, weeks or months are included as parameters, the parameters may be calculated using a formula. For an explanation on how to use a formula, refer to the Panel help.
Job groups

(Job groups table)
This function is used for setting up automatic job handling. This is useful for periodical jobs to be run each day, week or month. The jobs to be run are linked to a job group. For each job group, the included jobs, and in which sequence the jobs should be processed, are specified. The job group can be defined with a scheduled time indication for running, in which case it is assumed that the group's time indication is later than the computer's time when the job is submitted; otherwise the job will be processed immediately.

The parameters to be used with each job are defined in the Job Parameter table. The same job may be involved in different job groups. By using different versions of the job for different job groups unique parameter values may be defined. Tip: A job group can be submitted using IBS Job control. In this case a call to the job group submit driver program (SYS048D) should be made.

Example:

Sequence Keyword Line Parameter
2 JOB 10 EXAMPLE
4 EXCBPGM 20 CHGASWCOM COMPANY (XX)
4 EXCBPGM 30 CALL PGM(SYS048D) PARM('100') 100=Job group id

Note: The planned time, job queue and priority defined by the job group will be used when the jobs within the job group are submitted although the corresponding submit keywords are defined in the IBS Job control. If the IBS Job control job stream is set up to execute both the MFG job groups and other IBS batch jobs, and these jobs should run in a specific sequence, the IBS batch jobs must also be submitted using the same job queue. Check the set-up in the IBSJOBCON job description.

Basic data

This section outlines the information that is common to all modules in IBS Manufacturing. Basic Data includes item information, item structure information (bill of material and bill of routing) and information about work centres and tools.

The item information contains basic data about all kinds of items, e.g. produced items, subassembly items, items purchased and included material. The item information is comprised of a number of panels including the basic information (item header), description/languages, purchase price lists, sales price lists, item texts, warehouse information and locations, information about item/supplier, unit information etc.

Basic data To do
Material structure and Operation list The material structure contains information about the material involved to produce the item. The operation list contains information about the equipment, personnel and operation sequence for manufactured items.
If your choice is to work with variants at structure level, the variants are registered here. You can use 999 variants for every item. Variants could be used when there is a need to have an alternative structure for the parent item, if part of the material structure and/or operational list deviate from the basic structure. Every variant may be named, and you may also specify the dimensions the structure is registered in, e.g. per 100 units. When creating a manufacturing order, choose the variant best suited for the current situation.

As another dimension it is also possible to use warehouse in the structure to indicate to which warehouse the item is supposed to be delivered to. This gives possibility to have different BOM/BOR on the same product, but depending on to which warehouse the item is produced in the bill of routing, for example, has a different set-up.

The following functions are included in the Structure maintenance and Operation lists:

  • Copy the entire Material Structure/Operations List. This is recommended when making a new registration of structures. You use copy functionality to make a replica of a similar structure, which you then adjust to the right "appearance" in the maintenance.
  • Mass-removal of material/component
  • Mass-substitution of material/component
  • Mass-update of quantity for a selected component
  • Mass-replacement of a work centre
  • Mass-update of operation times
  • Mass-replacement of tools
  • Re-numbering of operations
  • Re-sequence of components
  • The possibility to connect material entries to operations, which means that reservations of the material involved will be delivered at the current operation's start time.
  • Validity time for Material/Operations. With this function you can enter occasional structural entries. This means structural entries which are only valid for a certain period, or structural entries which have an expire date, respectively structural entries which start being valid from a certain date.
  • Extra operation texts to be printed on work documents may be attached to the operations.
  • Tools information may be registered for the operations.
  • Material text connected to a specific component in the bill of material that will be printed on the shopfloor document.
Maintenance bill of material On the Structure maintenance material panel you enter the component items for the parent item.

    Sequence
    Enter Sequence, (including a range e.g. 10, 20, etc.) to make it possible to add new material entries between the existing entries.

    Enter the relevant information in the following fields:

    Component Item
    Component Variant
    Quantity
    Operation no
    Enter the first operation number in use indicating which operation you want to attach the material to.

    The Valid from, Valid to fields are used if the material entry contains a temporary validity time, the validity of which starts/ends from or at a certain date.

    Position number
    The position number is used for sorting the manufacturing order shop-floor report "assembly report" in position order within the manufacturing order.
    Waste percentage
    Enter the amount in percentage. This field is used for enumerating the amount in the structure when reserving a picking for the manufacturing order.

    There is also the option to enter an allocation warehouse, when the material should be reserved somewhere else than the main item's warehouse.

    Break MRP
    Set to YES if the subassembly item should not be calculated (exploded) in MRP.
    Phantom item
    Set to YES if the subassembly item should not be produced on its own. This means that when a manufacturing order is created, the phantom entries and operations will be "lifted up" one level to the phantoms parent item.
Maintenance bill of routing On the Structure maintenance operation list panel, you define the operation sequence to be used to produce the item. At the top of the display the system displays a description of the item/variant, and the lot size for the same combination.

    Operations number
    Enter the operation number with ranges (e.g. 10, 20, etc.) to make it possible to add new operations between the existing ones.
    Description
    Enter a short operation description. It is also possible to add more extensive operational text to each operation.
    Work centre
    The group where the operation is taking place.
    Time basis code
    Signifies the quantity unit processed during the operation's time.
    Run/Labour time
    The processing time according to time basis code. If time basis code is left blank, time will be handled as time/unit or batch size entered; otherwise time basis code will be used.

    There are also time fields for Internal set-up time (used in workload planning), External set-up time (NOT used in workload planning), and Machine time. Internal set-up time indicates the original time planned for the operation. External set-up time indicates the extra time that must be added due to different circumstances.

    Tool 1, Tool 2
    Can be entered on the operation directly. If more than two fields are in use for one operation there is a possibility to add unlimited number of tools connected to one operation by using a special option from the bill of routing overview.

    For Sub-contractor operations, the Price and Supplier may be entered. The sub-contract price can be used in the product costing calculation. This information is also the default values used for creation of a purchase order from the manufacturing order module.

    Validity time for operations: Valid From, Valid To, is entered in the event that the operation has a temporary validity time, or is going to start/end from or to a certain date.

    Reporting operation
    Set to YES if this operation is an operation that should be reported on manufacturing order. If you set to NO the operation time will be back-flushed when the next operation is reported. This means that by setting reporting points at certain operations the system will back-flush the reporting for all operation from present operations to the previous reporting operation (milestone).

    Overlapping type (1 quantity and 2 percentage) and Overlapping value. This type is, in combination with the overlapping value, used to calculate operation planning dates overlapped in the following functions: Manufacturing order, MRP and Capacity clearance.

    Queue time
    If queue time is entered this is an override value from work centre.
    Transport time
    If transport time is entered this is an override value from work centre.
Work centres The work centre file is used to group the different resources available for the production. The file contains, among other things, information about prices, workload etc. By using this information you can control the costs for different machines, groups of machines, or other kind of resources. The information is also used for the detail planning and workload overview.

The Work centre maintenance consists of two panels to be completed.

The first panel is used to identify the work centre. The work centre code can be numerical, alphabetical or a combination of the two.

First panel:

The following information is mandatory on the first panel: Description, Calendar, Normal capacity, Work centre type, Workload type, Manfactor, Number of machines, Resources per job, Workload planning and Number of shifts. Number of shifts is only mandatory when the MPL-TIME (Plan operation by date/time function is inactive.

If the MPL-TIME (Plan operation by date/time) function is active then a scheme group must also be entered for work centres that are defined with workload planning *Yes. The scheme group consist of schemas, work time interval and breaks for a week.

Complete all other relevant information.

Department, Department section and Foreman are informational fields, used for selections.

If you choose to work with workload planning, it is governed by the values you enter in Efficiency factor, Manfactor, Number of machines and Number of shifts in conjunction with Calendar and your normal resource level for the work centre. The general Queue time andTransport time may also be entered to influence the workload calculations. For a description of workload calculations, see Calculations.

The different time prices (standard or action) and the overhead percentage (standard or actual) are used to calculate the product costing operation and the manufacturing costs in the product costing calculation and the cost control calculation.

Second panel:

On the second panel you can enter New prices per hour (standard or actual) and also New overhead percentage (standard or actual). The new values will automatically be used, when the date valid from occurs. Average prices has to be updated manually; this is only handled as an information field.

Structure unit handling Structure unit handling allows you to define the structure in another unit than stock unit. This information will be calculated to stock unit whenever the stock quantity is needed, e.g. product costing calculation, MRP, Pull-planning (shortage, priority analysis), manufacturing orders material issue and product reception.

The structure unit and/or unit on the material lines will also be used in the manufacturing order process allowing the user to do the reporting on the unit defined for the item (structure) or the stock unit.

To be able to use Structure unit handling and view this information in the system, the following must be defined:

  • The unit to be used in the structure must be defined and the Allowed on BOM flag must be set to YES. (Item file, Units).
  • The structure itself must be defined with the structure unit. (Work with structure, Structure header).