May 2011 V6.1. Training Course. OP203: Fundamentals Manufacturing
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- Austen Bates
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1 May 2011 V6.1 Training Course / Sage 2010
2 Timing and Breaks Because our brains are not computers, we will have a break every hour and quarter, here is the daily schedule : Please feel free to use your mobile phones or check your s during these breaks. If you wish to meet someone, you can inform him or her about the above schedule. 2 / Sage 2010
3 Presentation Who are you? What are your expectations of this course? 3 / Sage 2010
4 Sage ERP X3 Fundamentals Sage ERP X3 Advanced Sage ERP X3 Expert CB Introduction & Functional Overview (3 days) TEC102 FIN201 - Finance (4 days) OPE201 - Distribution (3 days) OPE202 - Inventory (2 days) You Are Here Development (4 days) TEC103 Installation (4 days) OPE203 - Manufacturing (3 days) TEC101 - Common Tools (3 days) Distribution Contracts (Purchasing and Sales) Loan Orders Packaging & Shipment Preparation Purchasing Signature Management Sales and Purchasing Prepayments Sales Reps and Commissions Sourcing: RFQs, Responses Carrier Management Inter-Site and Intercompany Transactions Invoice Elements (Purchasing & Sales) Kits, Options & Variants Price List Management (Advanced) Manufacturing (4 days) Advanced Global Manufacturing Production Costing and WIP Posting Finance Bank Communication & Reconciliation Budget Control/ Analytical Budget Financial Data Extraction Statements & Reminders Automatic Journals & Dimension Defaults Advanced Payment Transactions Month and Year End Processes Fixed Assets Inventory (3 days) Allocation Rules (Advanced) Stock Counts Serial Number Management Reodering Replenishment Storage Plan Valuation Methods and Price Adjustments and cost calculations Quality Control & Sampling Tools & Development Advanced Common Tools Advanced Development Distribution and Inventory Purchasing Subcontracts Pre-Allocations (Pegging Function) Radio Terminals Manufacturing (5 days) Configurator Weighing Optimisation ILOG Finance Multi-Legislation Set Up Operating Budgets Stock Interface Pre-Consolidation Analytical Allocations Factoring Tools & Development Connectors Java Bridge Serveur Components Eclipse LDAP integration Interface Import/Export Netvibes Sage Search 4 Course Map Title of the Presentation
5 Objectives To be able to create a manufacturing data set. To be able to manage the priority and capacity planning through Sage ERP X3. To understand all the possibilities in the manufacturing flow : WO creation and modification Tracking Closing Costing 5 / Sage 2010
6 Pre-requisites Sage ERP X3 Introduction (CB101) Sage ERP X3 Functional Overview (CB102) Sage ERP X3 Inventory (OPE202) Knowledge on Manufacturing management 6 / Sage 2010
7 Course Contents Preamble Work Orders Common data Work Order Management Capacity and Load Modifying Work Orders Tracking Work Orders close and cost Appendix 7 / Sage 2010
8 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 8 / Sage 2010
9 1. Preamble Chapter Objectives and Contents Chapter Objectives Chapter Contents Understanding the CIM (Computer Integrated Manufacturing) context The definition Understanding the priorities analysis Understanding the Planning Methods The planning sequence Introduction to Volume-Variety illustration Available tools 9 / Sage 2010
10 Understanding the CIM context Definition Focuses on managing a certain volume of data Manages priority planning and capacity planning Answers questions: what do I need to produce, when, how many and how It tends to reduce stock, shortages, delays It gives real time reports Data must be accurate Continuous improvement efforts are recommended (to shorten lead times, avoid waste ) Updating of data must be rigorous 10 / Sage 2010
11 Understanding the priorities analysis The planning sequence PLANNING SEQUENCE MATERIAL DRIVEN CAPACITY DRIVEN 1 PRODUCT PRODUCT 1 S&OP*, Forecast, MPS* 2 PRIORITY PLANNING CAPACITY PLANNING 2 MRP* Finite capacity 3 CAPACITY PLANNING MATERIAL PLANNING 3 Finite capacity MRP * S&OP : Sales & Operations Planning * MPS : Mastered Production Scheduling * MRP : Material Requirement Planning 16 / Sage 2010
12 Understanding the Planning Methods Demand lead time constraints and cumulative lead time ETO MTO ATO FTO MTS. Customer Lead Time ETO : Engineer To Order MTO : Make To Order ATO : Assemble To Order FTO : Finished To Order MTS : Make To Stock Competition responses? 18 / Sage 2010
13 Understanding the Planning Methods and Tools Introduction to Volume-Variety illustration: the 4 zones Variety ETO 1 Project Job shop MTO 2 Intermittent ATO 3 Batch Repetitive Line FTO Continuous 4 MTS Volume 20 / Sage 2010
14 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 21 / Sage 2010
15 2. Work Orders Chapter Objectives and Contents Chapter Objectives Understanding work order place inside the X3 ERP CIM module Clarify the necessity of the manufacturing releases in the industrial firm Understanding the different status of a work order Understanding the decision tools to make the work done by the industrial firm operators Understanding the work order printing logic Chapter Contents The module logic Definition of a Work Order The Demand/Supply balance logic Life of a work order Time fences and possible actions Short term and medium term horizon logics Load/Capacity balance logic to complement the Demand/Supply balance logic Learn about the Work Order shop packet content 22 / Sage 2010
16 Understanding work order place inside the CIM module The module logic Manufacturing planning Work orders management Dispatch Production tracking Demand analysis Data base management CIM Feedback Improvement Common data Product categories Products Product site Bill of Material Routing Demand X3 Forecasts entries X3 Sales order Manufacturing MPS-MRP Workbenches Analysis (Materials & Loads) Purchases Releases Modifications Prints Tracking Material tracking Operation tracking Production tracking Feedback Costing Reports Comparisons 23 / Sage 2010
17 Exercise 2.1 Preparation 24 / Sage 2010
18 Understanding work order place inside the CIM module Work order definition BOM* Routing Product * BOM : Bill Of Material Work Order 25 / Sage 2010
19 Understanding work order place inside the CIM module Complete manufacturing flow Single WO or Mass allocation Single WO or Mass scheduling Single WO or Mass Single WO or Mass Single WO or Mass Single WO or Mass Single WO or Mass Single WO or Mass WO Planned WO Firm Stock allocation Load scheduling WO shop packet Time tracking Material tracking Completed Qty tracking Closure/ Completion Costing Automatic Automatic Automatic Automatic Automatic Automatic 26 / Sage 2010
20 Understanding work order place inside the CIM module Common flow Work Orders (GESMFG) Stock Change (GESSCS) Production Tracking (GESMTK) Work Order Close (FUNMCLOSE) WIP Finalization (FUNWIPMFC) Time Tracking (FUNBENCHO) Work Orders (GESMFG) Manufacturing Plan (FUNBENCHI) Mass closure/ completions (FUNTDUCLO) WIP Finalization (FUNWIPMFC) Material Tracking Plan (FUNBENCHM) BOM and Routing Work Orders (GESMFG) Production tracking (GESMFG) Work Order Close (FUNMCLOSE) WIP Finalization (FUNWIPMFC) Product 27 / Sage 2010
21 Priority planning The Demand/Supply balance logic Category Product Product site Bill of Material S&OP MPS MRP PAC S&OP : The forecast values and requirements from the sales information system and costing/profitability analysis are inputs to the Sales and Operations Planning phase. MPS : Master Schedule items are planned (those items that greatly influence profits or consume critical resources). Planning the master schedule items separately leads to a reduction in stock levels and improved delivery performance. MRP : Materials requirements planning is the final step in the planning process. The output of MRP is either a planned work order, a purchase requisition, or a planned purchase order. PAC : Production and Activity Control (Tracking) Demand Supply 28 / Sage 2010
22 Understanding the main status of a work order Order status Release Suggested Plan Planned Release Firm Close Physical Process Closed Life of a Work Order WO shop packet Tracking Complete Costing Pending Printed In Completed progress Closed & Costed 29 / Sage 2010
23 Understanding time fences and WO status Time fences and possible actions Volume Firm Time Fence DTF* PTF* End of Buckets SOF SOS SOS SOF WOF WOF SOF Flexible WOS WOS Free WOP SOP SOP SOS Frozen WOF WOP WOP SOP WOS 2 to 3 weeks 8 to 12 weeks 16 weeks t Product Sites General Parameter Requirements Parameters * DTF : Demande Time Frence * PTF : Planning Time Fence * LT : Lead Time 30 / Sage 2010 Firm horizon 2 Demand horizon 3 GPLNHOR 10 Day 60 Week 4 Month 1
24 Work orders Manufacturing > Planning > Work Orders Site. Main features of a work order Release Mode complete materials only operations only Quantity & Unit (Released) Default value from product-site Misc. Information Project; Lot; Source document; WO designation Routing Default value from product-site Order status Product (Released) BOM Code Planning Information Alternate Planned Firm Scheduling mode; Start Date; End Date; Priority 31 / Sage 2010
25 Exercise 2.2 Create a work order 32 / Sage 2010
26 Understanding the decision tools Priority planning Capacity planning Load/Capacity balance logic to complement the Demand/Supply balance logic Category S&OP RRP* Work centers Product MPS RCCP* Routing Product site MRP CRP* Operation Bill of Material PAC Input Output control Demand Load Supply * RRP : Resource Requirements Planning * RCCP : Rough Cut Capacity Planning * CRP : Capacity Requirements Planning 33 / Sage 2010 drives constraints Capacity
27 Exercise 2.3 Demand-Supply balance inside the work order 34 / Sage 2010
28 Exercise 2.4 Recalculate the loads 35 / Sage 2010
29 Exercise 2.5 Load-Capacity balance inside the work order 36 / Sage 2010
30 Understanding the Work Order printing logic Learn about the WO shop packet content 38 / Sage 2010
31 Exercise 2.6 Print the work order 39 / Sage 2010
32 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 40 / Sage 2010
33 3. Common Data Management Chapter Objectives and Contents Chapter Objectives Understanding the priority planning structuring 1/2 Understanding the capacity planning structuring Understanding the priority planning structuring 2/2 Defining concepts around common data Chapter Contents The product category The product The product site The Work center The routing The bill of material Mass Changes to common data 41 / Sage 2010
34 Product Product-Site Product category Product category Site Understanding the priority planning structuring Product category Rules Rules Product data Default value Product data Product- Site data Product- Site data Product- Site data / Sage 2010 Fundamental Inventory Sage ERP X3 v6
35 Understanding the priority planning structuring Focus on Stock management SO* SO* SO* SO* Available stock By order WOS WOS WOS Link with order number The order management strategy: the customer, its order number and the project designation are kept on the orders 43 / Sage 2010
36 Understanding the priority planning structuring The category, Entry flows tab Location A default location can be proposed during an entry. The description (area) given by the column aims to make it easy to find the good location type and/or the location in the product site Status If the document and/or the product definition don t force the Q status, a default status can be proposed per entry transaction Management rules QC entry The entry can trigger an analysis request Lot entry If the product is lot managed we can control if the lot exists in the database Lot by default A sales order or a work order number can be used as the lot number 44 / Sage 2010
37 Understanding the priority planning structuring The category, Issue flows tab Allocation rules Stock lines determination rules applied on Sales & Work orders Global locations Applied if a global allocation policy is used Issue flows tab Issue rule Stock lines determination rules applied during issues Management rules Each movement type can be customized 45 / Sage 2010
38 Understanding the priority planning structuring The category, Planning tab Planning Definition of horizons in order to manage time fences Planning tab Manufacturing Different lead times which have consequences on the end date and the start date of the orders Reordering Depending on the planner managing decisions, different reordering rules can be set and adjusted Parameters Depending on the reordering choices some data here are mandatory 46 / Sage 2010
39 Exercise 3.1 Product Categories Set Up 47 / Sage 2010
40 Understanding the priority planning structuring The product status Entries Issues Bill of Material WO (Component) WO (Parent product) Sales orders Purchase orders Active In Development Shortage Not Renewed Obsolete Not usable Warning Warning Warning Warning KO message message message message Always OK Always OK OK Warning message Warning message Warning message KO OK Warning message Warning message Warning message Warning message Warning message KO (product not loaded) Warning message KO (product not loaded) Warning message KO (product not loaded) KO KO KO Warning message Warning message KO KO KO KO MRP OK OK KO KO KO 48 / Sage 2010
41 Understanding the priority planning structuring The product, Identification tab Common Data/Product/Product Miscellaneous Individual information on the product Use Is the product submitted to a lifecycle? Identification tab Image This image is stored in the database 49 / Sage 2010
42 Understanding the priority planning structuring The product, Control tab Inventory parameters Recontrol/Expiration The product, Tool bar Inquiries Functions Costing 50 / Sage 2010
43 Exercise 3.2 Product Set Up 51 / Sage 2010
44 Understanding the priority planning structuring The product site, Controls tab Common data > Products > Product-Sites Product site: Common data used to personalize the stock management rules (location management, reorder policies) and production rules on a given site Quality Sampling 52 / Sage 2010
45 Understanding the priority planning structuring The product site, Planning tab Planning Lead times Reordering Re-planning 53 / Sage 2010
46 Understanding the priority planning structuring The product site, Planning tab EOQ (Economic Order Quantity) Lot sizing 54 / Sage 2010
47 Understanding the priority planning structuring The product site, Stock tab Internal stock situation External stock situation The product site, Totals tab Entries Issues 55 / Sage 2010
48 Understanding the priority planning structuring The product site, Calculated data tab Entry data Calculated data The product site, Manufacturing tab Routings Parameter definition 56 / Sage 2010
49 Understanding the priority planning structuring The product site, Cost tab Valuation For all kinds of flow, what will be the right valuation rule? Overhead cost Usable if the material or the part or the sold good has got indirect costs Cost tab Cost calculation Manual entry for components unless calculation process is launched using last price for example. Calculated for produced goods. Unit price AVC, Last receipt cost & standard cost are broken down into details 57 / Sage 2010
50 Exercise 3.3 Product-Site Set Up 58 / Sage 2010
51 Understanding the capacity planning structuring The Work Center Head of work center Controls tab Variation tab Replacement tab Load tab 59 / Sage 2010
52 Exercise 3.4 Work Center Set Up 60 / Sage 2010
53 Understanding the capacity planning structuring The Routing Head of routing Header tab Routings tab Scheduling 61 / Sage 2010
54 Understanding the capacity planning structuring Focus on routing and usefulness Actual WO cost roll up after closing RCCP (MPS) Provisional and WO cost roll up Routing Load & scheduling calculation during releases CRP (MRP) 62 / Sage 2010
55 Exercise 3.5 Routing Set Up 63 / Sage 2010
56 Understanding the capacity planning structuring Focus on routings tab, detail operation the different types of time Time in hours Time set in the head of the routing Time in hours Preparation fixed Setup fixed Run time Proportional Fixed or rate Load time of the Work Center Wait fixed Post Op fixed Interoperation time Load Cost Scheduling 64 / Sage 2010
57 Understanding the priority planning structuring The Bill of Material BOM: describes the parent item In order to configure and test it (design department) In order to plan and create work orders (planning department and workshop) BOM: used for costing purposes Planning BOM: making easier the forecast entries, considering produced items of a family as components and the link quantities (as a percentage) are the weight of the product inside the family Used in MPS with a long horizon Aims to analyse the MWS created by the dependent demand (due to the planning BOM) 65 / Sage 2010
58 Understanding the priority planning structuring The Bill of Material Parent-component relationship Parent product Where-used Link x 2 Coefficient = "Link quantity" B Component 66 / Sage 2010
59 Understanding the priority planning structuring The Bill of Material The levels One level BOM Alternate 11 Multi-level BOM Alternate 11 Level 0 B C Level 1 G H B C D Level 2 B 67 / Sage 2010
60 Understanding the priority planning structuring The Bill of Material Phantom Bill Assembly A Assy J Assy K Comp 1 Comp 2 Comp 3 Assy L Comp 12 Assembly A Assy J Assy K Assy P Assy L Comp 12 Comp 1 Comp 2 Comp 3 68 / Sage 2010
61 Exercise 3.6 Bill of Material Set Up 69 / Sage 2010
62 Defining concepts around common data Mass changing to common data Work Centers master data Standard operations Routing operations Mass replace Work center Mass application of capacity variation Mass copy of routings Can be restricted to operations on Work centers where RCCP (Rough Cut Capacity Planning) = Yes This is the only possibility to copy a Routing from one site to another Mass deletion of Routings 70 / Sage 2010
63 Exercise Cost roll up = global common data verification 71 / Sage 2010
64 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 72 / Sage 2010
65 4. Work Order Management Chapter Objectives and Contents Chapter Objectives Chapter Contents Managing the WO creations Understanding the WO content Understanding the lead time & scheduling Managing orders in planning tools Life of a firm Work Order Product Lot Scrap Work Order & Scheduling Lead time Cycle time, throughput time Operation & material dates Operation scheduling Work order re-scheduled 73 / Sage 2010
66 Managing the WO creations Introduction: Managing Orders in Planning tools, Action/Vision Action Vision Planning Workbench Individual Individual Enterprise Planning Individual Multiple Grouping Global Individual 74 / Sage 2010
67 Managing the WO creations WO can be generated from many different sources : Suggestion (MRP, MPS, Reordering point, or periods) WO Shop packet Sales orders (Back to back, By order) Work orders Production Tracking Material requirement (e.g. Semi Finished good) 75 / Sage 2010
68 Managing the WO creations Managing Orders in Planning tools, kind of orders and files DEMAND SUPPLY SORDERQ Sales orders SOF POF PORDERQ Purchase orders ORDERS Forecasts MRP logic SOP SOS MWS MSS ORDERS Used for Planning & Inquiries EOS POP POS WOS PREQUISD Purchase requests Reorder, periodic or MRP logics MWP MSP EOP WOP MWF MSF EOF WOF MFGMAT Material Work Orders MFGITM Produced goods 76 / Sage 2010
69 Managing the WO creations Nature Release of a firm work order Release of a planned work order Generation of a suggested work order Nature of orders Release product Parent product of the BOM WOF WOP WOS Byproduct Component of the BOM BWF BWP BWS Component Component of the BOM MWF MWP MWS Opération routing Of the parent product OWF OWP OWS ORS Operation of the firm work (OWF) order Operation of the planned work (OWP) order (OWS/ORS) Load suggested in MRP/MPS 77 / Sage 2010
70 Managing the WO creations Managing Orders in Planning tools, Introduction 78 / Sage 2010
71 Exercise 4.1 Forecasts 79 / Sage 2010
72 Exercise 4.2 Sales orders 80 / Sage 2010
73 Exercise 4.3 MRP 81 / Sage 2010
74 Managing the WO creations Managing Orders in Planning tools Work Order Suggested From MRP & MPS From ROP Work Order Planned Direct release WO Transaction Work Order Planned Work Order Firm 82 / Sage 2010
75 Work Orders Workbench & Data filtering Data filtering Workbench entry transaction Criteria button Formulas 83 / Sage 2010
76 Exercise 4.4 Workbenches 84 / Sage 2010
77 Exercise 4.5 Actions in Workbenches 85 / Sage 2010
78 Managing the WO creations Managing Orders In Planning tools, set up entry transaction Authorized actions By users Type of Orders displayed Critical order Length of Actions Create/Modify WOP or WOF Check users in products/product sites Users can be hidden General parameter GPLNFLT SOF, SOP, WOS etc. Formulas General Parameter GPLNHOR Work Order Planned Work Order Firm Product Product site Resource Orders 86 / Sage 2010
79 Managing the WO creations Managing Orders in Planning tools For an «ALL» entry transaction, the possible actions are Planning Workbench Grouping Stock Inquiry Management data Connection to Planning Workbench Connection to Grouping Stock by site Set up & stock information on the product All Orders 87 / Sage 2010
80 Managing the WO creations Managing Orders in Planning tools For an «ALL» entry transaction, the possible actions are Plan/Order Plan/Initiate Plan/Subcontract Associated orders zoom Component Availability Component availability by date Available to Promise Operation load Conversion into a Purchase order (P/F) Conversion into a Work order (P/F) Conversion into a External order (P/F) View of the WIPs associated with the WO and connection to the planning workbench Component availability enquiry for the WO Component availability by date enquiry for the WO Component available to promise enquiry for the WO If the WOS is scheduled WOS 88 / Sage 2010
81 Managing the WO creations Managing Orders in Planning tools For an «ALL» entry transaction, the possible actions are Modify/Initiate Work Order Scheduling Operation load Modify the order or convert into a firm Work order Tunnel to the Work order Schedule functionality If the WOP is scheduled WOP Modify Allocate Assignment Operation load Modify the order Allocate the Work order Assignment function If the WOF is scheduled WOF 89 / Sage 2010
82 Managing the WO creations Managing Orders in Planning tools For an «ALL» entry transaction, the possible actions are Plan/Order Plan/Initiate Plan/Subcontract Work Order Associated orders zoom Manual allocation Available to Promise Assignment Operation load Multi-level planning Conversion into a Purchase order (P/F) Conversion into a Work order (P/F) Conversion into a External order (P/F) Tunnel to the Work order View of the WIPs associated with the MW (pegging & horizontal dependencies) and connection to the planning workbench The component can be allocated Component available to promise enquiry for the WO Assignment function Load of the linked operation scheduled Release of the product structure resources MWF 90 / Sage 2010
83 Managing the WO creations Managing Orders in Planning tools For an «ALL» entry transaction, the possible actions are Work Order Associated orders zoom Available to Promise Tunnel to the Work order View of the WIPs associated with the SC and connection to the planning workbench Service available to promise enquiry for the SC SCP Order Work Order Associated orders zoom Available to Promise Assignment Conversion into a Purchase order (F) Tunnel to the Work order View of the WIPs associated with the SC and connection to the planning workbench Service available to promise enquiry for the SC Assignment function SCF 91 / Sage 2010
84 Understanding the WO content Life of a Firm Work Order Shop packet Tracking Close Costing Pending Printed In Progress Completed Closed + Costed Being Optimized Optimized Possibly suspended 92 / Sage 2010
85 Understanding the WO content Lot Management General parameter LOTMGT In planning WOP LOT In release WOF1 LOT1 WOF2 LOT2 At first tracking Track1 LOT1 Track2 LOT1 No (stock rules applied) See Work order entry transaction if lot entered and entry flow, movement type in the category: Lot entry and lot by default + Lot sequence number (Controls tab, product) 93 / Sage 2010
86 Understanding the WO content Scrap I.e.: Quantity need Qn = 100, what is the Quantity to release Qr? X3 formula Qr = Qn (1 + scrap) APICS formula Qr = Qn (1 scrap) If Scrap factor = 50 % Case 1 (ERP X3) : Qr = 150 Case 2 (APICS) : Qr = / Sage 2010
87 Understanding the Lead Time & Scheduling Work Order & Scheduling Lead time Operation & material dates Operation scheduling Work order re-scheduled 95 / Sage 2010
88 Understanding the Lead Time & Scheduling Work Order & Scheduling Not scheduled Schedule Scheduled Reschedule Mark to reschedule Optimized 96 / Sage 2010
89 Understanding the Lead Time & Scheduling Lead time Resource Start date Manufacturing/ Procurement lead time Requested delivery date Shipment date Expected delivery date Resource End date Quality control lead time Delivery lead time Due date for X3 97 / Sage 2010
90 Understanding the Lead Time & Scheduling Operation & material dates Routing operation 0 Operation LT 0 26/MM/YY 30/MM/YY Order start date Op 10 Op 20 Op 30 Op 40 Produced item Material need date 98 / Sage 2010
91 Understanding the Lead Time & Scheduling Operation & material dates Work order Routing operation 0 Operation LT 1 26/MM/YY Order start date 30/MM/YY Op 10 Op 20 Op 30 Op 40 Produced item Material need date 99 / Sage 2010
92 Understanding the Lead Time & Scheduling Operation & material dates Work order scheduled only Routing operation 40 Operation LT 0 26/MM/YY Order start date 30/MM/YY Op 10 Op 20 Op 30 Op 40 Produced item Material need date 100 / Sage 2010
93 Understanding the Lead Time & Scheduling Operation scheduling Operation Next operation Scheduling Op. 10 Op. 20 Overlapping Op. 20 Op. 30 Start synch Op. 30 Op. 40 Start synch Op. 40 Op. 50 Successor Op / Sage 2010
94 Understanding the Lead Time & Scheduling Work order re-scheduling Schedule rules Parameters > Manufacturing > Scheduling Schedule Automatic Reschedule of arrears X Date of process SOF Manufacturing start date overshooted WOS Backward scheduling by default 102 / Sage 2010 WOS Automatic forward scheduling
95 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 103 / Sage 2010
96 5. Capacity and Load Chapter Objectives and Contents Chapter Objectives Chapter Contents Understanding the capacity Understanding the Load Capacity determination Load determination Load & Infinite Schedule 104 / Sage 2010
97 Understanding the Capacity Capacity determination General parameter: Default weekly structure Work Order STO/SCH PLNTWD Site Parameters > Organizational Structure > Sites Sites Unavailable FR10 Work Centers WC Weekly Structures SC1 No. of resources 2 Capacity variations 105 / Sage 2010
98 Understanding the Capacity Capacity definition for a work center 106 / Sage 2010
99 Understanding the Load Load & Infinite Schedule Work Center 1, Number of resources = 4; 7 hours per day Capacity is 28h / day Day Operation on WO1 23 hours in more than 3 days Number of resources =1 Operation on WO2 17 hours in 2.5 days Number of resources =1 Operation on WO3 40 hours in 5.7 days Number of resources =1 107 / Sage 2010
100 Understanding the Load Load & Infinite Schedule Work Center 1, Number of resources = 4; 7 hours per day Capacity is 28h / day Day Operation on WO1 23 hours in more than 3 days Number of resources =1 Operation on WO2 17 hours in 2.5 days Number of resources =1 Operation on WO3 40 hours in 5.7 days Number of resources =1 108 / Sage 2010
101 Understanding the Load Load & Infinite Schedule Work Center 1, Number of resources = 4; 7 hours per day Capacity is 28h / day Day Operation on WO1 23 hours in more than 3 days Number of resources =1 Operation on WO2 17 hours in 2.5 days Number of resources =1 Operation on WO3 40 hours in 1.4 days No. res =4 109 / Sage 2010
102 Understanding the Load Load & Infinite Schedule Work Center 1, Number of resources = 4; 7 hours per day Capacity is 28h / day Day Operation on WO1 23 hours in more than 3 days Number of resources =1 Operation on WO2 17 hours in 2.5 days Number of resources =1 Operation on WO3 40 hours in 1.4 days No. res =4 110 / Sage 2010
103 Exercise 5.1 Work Order generation, preparation for firm load 111 / Sage 2010
104 Exercise 5.2 Actions for priority planning balance 112 / Sage 2010
105 Exercise 5.3 Actions on load 113 / Sage 2010
106 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 114 / Sage 2010
107 6. Modifying Work Order Chapter Objectives and Contents Chapter Objectives Understanding the possible actions inside the work order Understanding tools to modify work orders Understanding the dates Chapter Contents Updating authorization Modifying components Modifying operations Planning regeneration Available functions Actions that have an impact on dates 115 / Sage 2010
108 Understanding actions inside the work order Authorization: DEFWORTYP general parameter 116 / Sage 2010
109 Understanding actions inside the work order Focus to a work order modification 117 / Sage 2010
110 Understanding actions inside the work order Modifying components Exclude/reactivate Add Replace 118 / Sage 2010
111 Understanding actions inside the work order Modifying operations Exclude/reactivate Add Replacement 119 / Sage 2010
112 Exercise 6 Work order 120 / Sage 2010
113 Understanding tools to modify work orders Available functions 121 / Sage 2010
114 Understanding tools to modify work orders Available functions 122 / Sage 2010
115 Understanding the dates Actions that have an impact on load & scheduling WO modifications that have an impact on operating loads Performing time tracking Load recalculation with re-scheduling Subcontract buying, considering the requested delivery date Transformation of a WOP in a WOF Manufacturing > Technical Data > Serial modifications > Work center/capacity variation Manufacturing > Batch processes > Work Orders > Upgrade 123 / Sage 2010
116 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 124 / Sage 2010
117 7. Tracking Chapter Objectives and Contents Chapter Objectives Understanding the principles Understanding the workbench tracking Chapter Contents Tracking definition Personnel IDs The single WO tracking Time tracking Production tracking Material tracking Reintegration 125 / Sage 2010
118 Tracking: Definition Tracking Material tracking Work Order Pending Printing In progress Completed Transaction Operation tracking Production tracking 126 / Sage 2010
119 Tracking : Entry transaction Track Immediate materials Manual issue Back flush All For manual components Automatic determination Allocation rules evaluated Not closed Miscellaneous Closed All Reject Message Personnel ID Message Tracking Material tracking Work Order Category Product site Transaction Operation tracking Production tracking 127 / Sage 2010
120 Tracking : Manual Manual 128 / Sage 2010
121 Tracking : Mass Mass 129 / Sage 2010
122 Tracking without a Work Order Tracking can be generated without a Work Order : BOM tracking for Completed quantity or Material Tracking Routing tracking for Time Tracking Work Center tracking for Time Tracking Time Tracking Work Orders Completed quantity Mass closure/ completions (FUNTDUCLO) Material Tracking 130 / Sage 2010
123 Tracking Combination Tracking can be combined or done automatically Time Tracking Work Orders Completed quantity (Manufacturing plan) Mass closure/ completions (FUNTDUCLO) Material Tracking Plan 131 / Sage 2010
124 Time tracking Milestone and time tracking Op No Milestone 10 No 20 Normal tracking 30 No 40 No 50 Range Op 10 will never be tracked Op 20 will be tracked alone Op 30 and Op 40 will only be automatically tracked at the tracking of Op / Sage 2010
125 Production Tracking Main features of a work order tracking Manufacturing > Production tracking > Production tracking Site. Tracking date operations (start/end) status of closure Filter Misc. Information Actual Labor WC; Labor time set factor; Labor Run time factor; Actual Set up time WO number Operation Tracking Actual WC Quantity rejected Actual Run time Unit Status operations (start/end) material tracking mgt status of closure Completed Quantity Filter Tot. Achieved Quantity Quantity tracked Misc. Stock Info. Misc. Stock Info. Location; Lot & Sublot; Serial Number; 133 / Sage 2010 Material Tracking Component Status
126 Time Tracking Manufacturing > Production tracking > Time Tracking Main features of a time tracking plan End Date (start/end); Work order (start/end); Operation (start/end); Released product (start/end); Routing (start/end); Work center (start/end); Site. Filter Time Type WO Product Miscellaneous Operation Misc. Information Actual Labor WC; Labor time set factor; Labor Run time factor; Actual Set up time ID Date Origin Actual WC Quantity rejected WO Number Routing + Alt No origin Actual Run time 134 / Sage 2010
127 Exercise 7 Work Order Tracking 135 / Sage 2010
128 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 136 / Sage 2010
129 8. Work Order Close and Cost Chapter Objectives and Contents Chapter Objectives Understanding the Work Order Close Understanding the Production costing Understanding Costing tools Chapter Contents Work Order close Mass closure Work Order reactivation Cost principles (Theoretical) Provisional (BOM + Routing) Release Provisional (WOF) Actual cost (Production Tracking) Cost decomposition Costing tools functions Cost transfer 137 / Sage 2010
130 Understanding the 3 status fields of a work order Order status Release Suggested Plan Planned Release Firm Close Physical Process Closed Life of a Work Order WO shop packet Tracking Complete Costing Pending Printed In Completed progress Closed & Costed Line Status Pending Tracking In progress Close Closed 138 / Sage 2010
131 Closure Time Materials Product Released WO Completed Close Close Close Close Load Allocation MWF WOF WIP 139 / Sage 2010
132 3 types of Cost (Theoretical) Provisional (BOM + Routing) Raw 1 Raw 2 Opé 1 Opé 2 Release Provisional (WOF) Raw 1? Opé 1 Another Work Center used? Raw 2 Opé 2? Raw 3 Actual cost (Tracking) Raw Opé 1 - ½ h Raw 2 Opé 2 Raw / Sage 2010
133 (Theoretical) Provisional Cost (Theoretical) Provisional TC/COS CLCSTD*MAT GPA/COS CLCSTDRAT GPA/COS SCAMAJ GPA/COS EFFCSTUSE GPA/COS OVECOLSTD Release Provisional Actual cost 141 / Sage 2010
134 Cost Breakdown (Theoretical) Provisional cost Material cost Comes from BOM Labour cost Comes from the costing dimension or from the Personnel IDs Machine cost Comes from the costing dimension Sub-contracting cost Comes from the costing dimension/operation price General expense cost Comes from material, product or costing dimension (Overhead) 142 / Sage 2010
135 Cost calculation : example 1 Material Unit cost Link Quantity STK Quantity Total for Machine EDRILL Set EDRILL Run EPRESS Set EPRESS Run Labour EDRILL Set EDRILL Run Total Unit Cost Cost for / Sage 2010
136 Cost calculation : example 2 Material Unit cost Link Quantity STK Quantity Total for Machine EDRILL Set EDRILL Run EPRESS Set EPRESS Run Labour EDRILL Set EDRILL Run Total Unit Cost Cost for / Sage 2010
137 Release Provisional Cost (Theoretical) Provisional Release Provisional GPA/COS CSTRCPORD TC/COS VLTMATEXT GPA/COS MFCRATEXT GPA/COS CLCWOCAUT TC/COS VLTSEMEXT Actual cost 146 / Sage 2010
138 Cost calculation : example 3 Material Unit cost Quantity Quantity Total for 100 Cost for Machine EDRILL Set EDRILL Run EPRESS Set EPRESS Run Labour EDRILL Set EDRILL Run Total Unit Cost / Sage 2010
139 Actual Cost (Theoretical) Provisional Release Provisional Actual cost Product site, valuation method (Cost tab), see first value Valuation GPA/COS MFCRATCPL GPA/COS OPRRATE GPA/COS OVECOLMFC 148 / Sage 2010
140 Exercise 8 Close and cost 149 / Sage 2010
141 Understanding the Costing tool WIP Finalization Monitoring & cost roll-up of orders costs Costing > Production costs > WIP finalization WIP valuation Monitoring of costs for orders in progress Costing > Orders In Process > WIP valuation Cost comparison Comparison between costs for one WO Costing > Performance Analysis > Cost Comparison Multiple cost comparison Comparison between costs for WOs Costing > Performance Analysis > Multiple Cost Comparison 150 / Sage 2010
142 Cost breakdown Product 1 Sub part 1 Sub part 1 Material Machine Machine Labour Labour Overhead Overhead Subcontract Subcontract 151 / Sage 2010
143 Course Contents 1. PREAMBLE 2. WORK ORDERS 3. COMMON DATA 4. WORK ORDER MANAGEMENT 5. CAPACITY AND LOAD 6. MODIFYING WORK ORDERS 7. TRACKING 8. WORK ORDERS CLOSE AND COST 9. APPENDIX 152 / Sage 2010
144 Appendix Chapter and Contents Chapter Contents Common data General parameters & Activity Code Work Orders General parameters & Activity Code Work Order Management Flags and Updates 153 / Sage 2010
145 Common Data BOM: Activity Code, General Parameter Activity Code CD BOC General Parameter TC/BOM BOMLEV CD BOD TC/BOM BOMSTE CD BOW M UML I LOT 154 / Sage 2010
146 Common Data Routing: Activity Code, General Parameter Activity Code M MFO General Parameter GPA/ROU DEFWORTYP GPA/ROU ROUSTE GPA/MIS OPEEFFAPP GPA/MIS WSTEFFINH 155 / Sage 2010
147 Work Orders WO: Activity Code, General Parameter Activity Code M MFM General Parameter GPA/WOM CUMMAT M MFI GPA/CTL DOSFAB M MFO GPA/MIS LOTMGT 156 / Sage 2010
148 Work Orders WO Modification: General Parameter General Parameter Work Order GPA/WOM RELUPD GPA/MIS GRGENPLN 157 / Sage 2010
149 Work Orders Workbench & General Parameters General Parameters STO/MIS MFGMTSNUM Work Order STO/SCH GPLNFLT STO/SCH GPLNHOR ACH/AUZ BUYFLT 158 / Sage 2010
150 Work Orders Load/Scheduling: General Parameter General Parameter GPA/LOA SCHEDHOR 159 / Sage 2010
151 Work Orders Tracking & General Parameters Tracking GPA/CTL CTLALL GPA/CTL CTLFICTEC GPA/CTL MTKALLMGT GPA/CTL CTLOPEPRE GPA/CTL DOSFAB 160 / Sage 2010
152 Work Order management Flags and Updates, Head of Work Order Table Field LM Values Updates MFGHEAD MFGSTA Order Status = Firm 4 = Closed 4 on WO Close MFGTRKFLG Tracking flag or Situation = Pending 3 = Printed 4 = In progress 5 = Completed 6 = Closed + Costed 3 on printing 4 on 1 st tracking 5 when all details = 5 6 on Final Costing 161 / Sage 2010
153 Work Order management Flags and Updates, Manufactured goods of Work Order Table Field LM Values Updates MFGITM Product MFGSTA Order Status = Firm 4 = Closed 4 on WO Close ITMSTA Line Status = Pending 2 = In process 3 = Completed 2 on 1 st tracking 3 on Close in tracking MFITRKFLG Tracking flag = Pending 3 = Printed 4 = In progress 5 = Completed 6 = Closed + Costed 4 on 1 st tracking No change on full qty without Close 5 on Close in tracking 6 on Final Costing 162 / Sage 2010
154 Work Order management Flags and Updates, Components of Work Order Table Field LM Values Updates MFGMAT Material MFGSTA Order Status MATSTA Material status MFMTRKFLG Tracking flag = Firm 4 = Closed = Pending 2 = In process 3 = Completed = Pending 3 = Printed 4 = In progress 5 = Completed 6 = Closed + Costed 2 on 1 st tracking 3 on Close in tracking 4 on 1 st tracking No change on full qty without Close 5 on Close in tracking 6 on Final Costing 163 / Sage 2010
155 Work Order management Flags and Updates, Operations of Work Order Table Field LM Values Updates MFGOPE Operation MFGSTA Order Status = Firm 4 = Closed 4 on WO Close OPESTA Operation Status = Pending 4 = In process 5 = Completed 4 on 1 st tracking 5 on Close in tracking MFOTRKFLG Tracking flag = Pending 3 = Printed 4 = In progress 5 = Completed 6 = Closed + Costed 4 on 1 st tracking No change on full qty without Close 5 on Close in tracking 6 on Final Costing 164 / Sage 2010
156 THANK YOU 165 / Sage 2010 Fundamental Inventory Sage ERP X3 v6
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