BaanERP 5.0c Project. User's Guide for BaanERP Project - PCS Integration

Transcription

1 BaanERP 5.0c Project User's Guide for BaanERP Project - PCS Integration

2 A publication of: Baan Development B.V. P.O.Box AC Barneveld The Netherlands Printed in the Netherlands Baan Development B.V All rights reserved. The information in this document is subject to change without notice. No part of this document may be reproduced, stored or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Baan Development B.V. Baan Development B.V. assumes no liability for any damages incurred, directly or indirectly, from any errors, omissions or discrepancies between the software and the information contained in this document. Document Information Code: U7511B US Group: User Documentation Edition: B Date: October, 2001

3 Table of contents 1 Introduction Concept Procedures 3-1 Standard item 3-2 Standard item procedure through budget lines in project budget Actions Project: Actions Manufacturing: 3-5 Actions Enterprise Planning: 3-5 Actions Execution: 3-5 Actions Warehousing: 3-6 Actions Project: 3-6 Standard item procedure through directly creating planned warehouse orders 3-7 Actions Project: 3-7 Generic item Generic item procedure through budget lines in project budget Actions Project: 3-11 Customized (existing) item 3-13 Actions Project: 3-13 Multiple parts of (standard) manufactured item 3-14 Actions Project: 3-15 i

4 Table of contents ii

5 About this document This document describes the integration and process flows between BaanERP Project (TP) and Projects (PCS) in BaanERP Manufacturing. The document is created for the BaanERP 5.0c release Service Pack 6. Deviation can exist between this document and older versions of the software. Chapter 1, Introduction, introduces the specific needs to the Industrial Project market. Chapter 2, Concept, describes how to create a PCS link. Chapter 3, Procedures, describes three procedures: Standard item, Generic item, and Customized item. iii

6 About this document iv

7 1 Introduction The Industrial Project market has specific needs with regards to software solutions. Both Project Management and Manufacturing are part of their daily business and must be available in an integrated application. BaanERP offers these possibilities. This document describes the procedure for the integration between BaanERP Project and BaanERP Manufacturing. Some basic knowledge of BaanERP is required to apply this procedure. 1-1

8 Introduction 1-2

9 2 Concept In general, you can create a Projects (PCS) link with the following procedures: Standard (manufactured) item. Generic item. Customized item. From a manufacturing perspective, the item selection depends on the product specification decoupling point. The lowest level of customer involvement in the product specification is the standard item. In this situation, the customer can only choose different items from a catalogue. To produce a standard item for a specific project, the item is produced on order. This requires a PCS project with the Standard item procedure. If the generic item is selected, the customer has influence in the product specification by selecting the product options. The configured generic item also requires a PCS project to be produced with the Generic item procedure. If the customer demands product changes to meet its requirements, it is called customizing. There are three approaches to develop such a customer specific product. Modify a standard item. Modify a configured item. Modify a previous customer specific item. If one of the options is used as a base, it has a significant impact on the product engineering process. One of the three procedures can be used depending on the selected base. In the highest level of customer involvement, the product development is fully engineered products. For a fully engineered item, you must start at the beginning. In which case, you can start with the definition of an item through a PCS project. This customized item is linked to BaanERP Project. This is handled with the Customized item procedure. In some situations, you can select and budget parts of the items separately. This multiple-part selection is described later in this document. 2-1

10 Concept 2-2

11 3 Procedures In this chapter, three procedures are described: Standard item. Generic item. Customized item. In general, there is no difference in the process flow of the Project Requirements Planning if an element or activity structure is used. However, the following must be taken into account if an activity (control) structure is used: If the External Scheduling Package integration is used, the start date and the finish date of activities can also be set up in Microsoft Project or Open Plan Enterprise. You can use start dates and finish dates for each budget line, which can differ from the start dates and end dates of the activity. You can link a milestone to a customized item. This milestone can be automatically set to Reached through an update session. In this way, you can update the progress of the PCS project in the project schedule. There are two ways to create a link with BaanERP Project and PCS: Through Budget lines in Project Budget. Through directly making Planned PRP Warehouse Orders in the Project Requirements Process. If this option is used, a budget will not be created for this item in Project Budget. 3-1

12 Standard item When a standard, manufactured, item for PCS integration is used through Project Requirements Planning, the item in the General Item Data (tcibd0501m000) session has the following mandatory settings: 1 On the Item Data tab, the item type must be Manufactured. 2 On the Subentities tab, you must select the Ordering Data option. 3 The Order Policy must be To Order. 4 The Order System must be Planned. 5 You must select the Project Data option, the Project Order System option, and the PRP option. 6 The Planning Data field must be filled. The Order Horizon option determines until what (future) time, the planning scenario will be taken into account. You must set the duration at minimal to the largest cumulated item lead-time. If the horizon is not large enough, BaanERP will not plan the required orders. Standard item procedure through budget lines in project budget Actions Project: 1 Start the Maintain Projects (tppdm6500m000) session to define a project; you can use an element or activity budget. You can link a default project warehouse to either the project or in more detail, to the element or activity. In this way, the project warehouse will be set to the Generated PRP Warehouse Orders. This procedure assumes you are able to maintain the remaining parts of the project definition. However, you must change the project status to Active when you carry out step 5. 2 Define activity, Charge Breakdown Structure, and/or elements, depending on the types of budget you want to use. You can link a default project warehouse to the element or activity. In this way, the project warehouse will be used when Generating PRP Warehouse Orders. This procedure assumes you have set up the element and/or activity structure. However, you must change the element and/or activity status to Actual when you carry out step

13 3 Start the Element Budget (tpptc1810m000) session or the Activity Budget (tpptc2810m000) session, select the Material Cost type and select the appropriate project and element or activity. On completion, insert a Manufactured item, which you produced in a PCS project. The order policy must be To Order. 4 To manufacture the budget line, you must customize the To Order Manufacturing item. There are two ways of doing so: Click Make Customized on the budget line. Start the Customize Items in Budget (tpptc1255m000) session. This session will customize all relevant items in your budget. This option is convenient when you want to copy projects. During the customization process, you can create a new PCS project or select an existing PCS project. You must take into account that each PCS project requires multiple steps to close and archive. During the customization, BaanERP prompts you to perform a cost price calculation for this customized item. Click Yes to calculate the cost price. This cost price can differ from the standard cost price. Depending on the number of items, the costs of setup times for example, can vary. With the Cost Price button you can update the budget line with the newest cost price. As a result, you will have a customized item that is copied from the standard item. The system will add the PCS code in front of the item code and automatically create a PCS project. This PCS code depends on a default serial number, which can be defined in the General Parameters (tppdm0100s000) session. On the Defaults tab, select the Serial Number for PCS Project option. The serial number is linked to a calculation office in the Default Project Data by Number Group (tipcs0503m000) session. The enterprise unit that belongs to this calculation office, which is a department, must be the same as the enterprise unit that belongs to the project in Project and project warehouse. The number group data for PCS projects is stored in the General Parameters (tpdm0100s000) session. The number group selected in the General Parameter must have its defaults in the PCS (tipcs0100m000) session. The link between the PCS project and Project project can be found in the Project-PCS Relationships (tppdm6150m000) session. If the item in the budget has not customized, the Project requirement Planning will suggest to purchase the item. 3-3

14 5 Start the Control Data (tpptc1230m000) session. The main purpose of this session is to produce the control budget including data and structure. This session determines the information that is displayed in the project monitoring. The Project status must be Active and the Project Structure status must be Actual. 6 Start the Planned PRP Orders (tppss6200m000) session. Depending on the budget lines, BaanERP will check the requirements for the project. Consider, for example, one (manufactured) item line, this will result in one warehouse order, even if you have selected a customized purchase item. If a default project warehouse is not defined at the level of the project or element or activity, the Planned PRP Warehouse Order will deliver from the normal warehouse, priority warehouse, in the Projects (tppdm6500m000) session to the project. Alternatively, the PRP Warehouse Order will deliver the customized item from the normal warehouse to the project warehouse. If you select the Confirm Planned Orders option, you can skip the following step. 7 Start the Planned PRP Warehouse Orders (tppss6515m000) session to confirm the Planned order. Double-click the order line and on the Order/Delivery tab, change Order Status option to Confirm. You can also use the Confirm Planned PRP Warehouse Orders (tppss6225m000) session. 8 Start the Transfer Planned PRP Warehouse Orders (tppss6235m000) session to transfer the order. This transfer will generate a report with a new order number. You must write down, or print this number for further use in the procedure. An actual warehouse number now replaces the recommended warehouse order. This warehouse order will be referred to later on. Optional steps: To update the project schedule with the progress on the shop floor, you can use milestones. Milestones can be linked to customized items that are manufactured with the help of the PCS Project (tppss2501m000) session. Start the Check Customized Item Completed (tppss2203m000) session to check if the production of the customized item is completed. If the production of the customized item is complete, the linked milestone will be set to Reached. In addition, updating the production progress through milestones, can calculate the expected due date of the ordered customized items. In the Print PCS Planning Data (tppss6451m000) session, the production delays and rushes are looked up to display the expected due date versus the original date. 3-4

15 Actions Manufacturing: 9 Start the Project Status (tipcs2502m000) session to change the PCS Project status to Active. For Customized items (type C), you can now make changes by modifying the product. In project engineering in PCS, you can copy the drawing part of the product structure from previous projects or standard items. In BOM and ROU you can make specific changes. Actions Enterprise Planning: 10 Start the EP Parameters (cprpd0100s000) session to check the actual scenario number. This number is required to simulate orders. 11 Start the Simulate Orders (cprrp1210m000) session to generate the planned orders. There are three types of orders: Planned Production. Planned Purchase. Planned Distribution. The choice between the first two types of orders is influenced by: The Item type defined in the General Item Data (tcibd0501m000) session. The Default supply source in the Plan Item Data (cprpd1101s000) session. The Sourcing Strategy (cprpd7110m000) session. Planned distribution orders are used if available stock can be used. 12 Start the Planned Orders (cprrp1500m000) session to select one order and click Confirm, or start the Confirm Planned Orders (cprrp1200m000) session to select a range of orders to confirm. 13 Start the Transfer Plan/Order (cppat1210m000) session to transfer the production order. Actions Execution: 14 Depending on the order types, you must select manufacturing, purchase or warehousing procedures. These procedures will not be described in this document but can be referred to in the Shop Floor Control (SFC), Warehousing (INH) and Purchasing (PUR) module descriptions. 15 After completion of the required procedures, the finished item is posted to a normal warehouse. Close the PCS project according to the module description of PCS. Note that the PCS project can only be deleted after you have deleted the BaanERP (TP) project. 3-5

16 Actions Warehousing: 16 As the item, in step 15, is stored in a general warehouse, the item must be transferred to a project warehouse or to the project. As a result of the PRP in Project in step 7, this order has been created but has not yet been executed. Use this order to ship the data from the warehouse to the project warehouse or the project. This procedure can be found in the Warehousing module description. 17 If the item is delivered to a project warehouse instead of directly to the project, you still need to ship from the project warehouse to the project. You must create a manual warehouse order to accomplish this step. This procedure can be found in the Warehousing module description. Actions Project: 18 Start the Confirm Commitment and Costs (tpppc4811m000) session to confirm the costs of the manufactured item. Select the cost line and select the specific function to approve the cost line. You can also use the Global Confirming (tpppc4200m000) session to confirm the cost line. 19 Start the Process Transactions (tpppc4802m000) session and the costs of the manufactured item will be posted to the project as material costs. 3-6

17 Standard item procedure through directly creating planned warehouse orders Actions Project: 1 Define a project in the Maintain Projects (tppdm6500m000) session; you can use an element or activity budget. You can link a default project warehouse to either the project or in more detail, to the element or activity. In this way, the project warehouse will be set to Maintaining PRP Warehouse Orders. This procedure assumes you are able to maintain the remaining parts of the project definition. However, you must change the project status to Active when you carry out step 3. 2 Define activity, Charge Breakdown Structure, and/or elements, depending on the types of budget you want to use. You can link a default project warehouse to the element or activity. In this way, the project warehouse will be set when maintaining PRP warehouse orders. This procedure assumes you have set up the element and/or activity structure. However, you must change the element and/or activity status to Actual when you carry out step 3. 3 Start the Planned PRP Warehouse Orders (tppss6515m000) session to insert the standard item. Use the following options: Delivery Type: Wrh-Proj. Warehouse: The warehouse of the item must be a nettable warehouse to plan the production for the item. Project Warehouse: To store the customized item in the project warehouse, you must fill the project warehouse before using it in the project. 4 With the specific function you can select the Make Customized option. As a result, BaanERP will add the PCS code in front of the item code and automatically create a PCS project. You have the option to create a new PCS project or to select an existing PCS project. Finally, the PCS project is linked to the BaanProject. This is visible in the Project-PCS Relationship (tppdm6150m000) session. 5 Confirm the Planned Order by selecting the Order Status option on the Order/Delivery tab. 6 Carry out the same steps, starting at step 8, of the Standard item procedure through budget lines in project budget section earlier in this chapter. 3-7

18 Standard Manufact. Item Material Budget Line Generate Control Data Make Customized (See detail flow) Generate Planned PRP Orders Confirm Planned PRP Warehouse Orders Planned PRP Warehouse Orders Standard Manufact. Item Transfer Planned PRP Warehouse Orders Make Customized (See detail flow) (Actual) Warehouse Order Execution Manufacturing / Order Management Execution Warehousing Confirm Costs Process Transactions Costs of Manufactured Item Figure 1 Flow for standard to order item 3-8

19 Make Customized Yes Use existing PCS project No Select the existing PCS project create new No PCS project PCS project linked Customize the product structure Yes Cost Price Calculation? Cost Price Calculation No Customized item Figure 2 Detailed flow make customized 3-9

20 Change PCS Project Status Simulate Orders Confirmed Planned Orders Transfer Planned Orders Close PCS Project Figure 3 Flow in PCS and Baan Enterprise planning 3-10

21 Generic item When a standard, manufactured, item for PCS integration is used through Project Requirements Planning, the item in the General Item Data (tcibd0501m000) session has the following mandatory settings: 1 On the Item Data tab, the item type must be Generic. 2 On the Subentities tab, you must select the Ordering Data option. 3 On the Subentities tab, you must select the Project Data option. 4 The Order Policy must be To Order. 5 The Order System must be Planned or Manual. 6 The Planning Data field must be filled. The Order Horizon option determines until what (future) time the planning scenario will be taken into account. You must set the duration at minimal to the largest cumulated item lead-time. If the horizon is not large enough, BaanERP will not plan the required orders. Generic item procedure through budget lines in project budget Actions Project: 1 Define a project in the Maintain Projects (tppdm6500m000) session; you can use an element or activity budget. You can link a default project warehouse to either the project or in more detail, to the element or activity. In this way, the project warehouse will be set to the Generated PRP Warehouse Orders. This procedure assumes you are able to maintain the remaining parts of the project definition. However, you must change the project status to Active when you carry out step 5. 2 Define activity, Charge Breakdown Structure, and/or elements, depending on the types of budget you want to use. You can link a default project warehouse to the element or activity. In this way, the project warehouse will be set when Maintaining PRP Warehouse Orders. This procedure assumes you have set up the element and/or activity structure. However, you must change the element and/or activity status to Actual when you carry out step 5. 3 Start the Element Budget (tpptc1810m000) session or the Activity Budget (tpptc2810m000) session, select the Material Cost type and select the appropriate project and element or activity. On completion, insert a Generic item. You can create a Planned Warehouse Order directly, as described previously for the Standard item. 3-11

22 4 Click the Configurator button. Depending on the setting in the Companies (tccom0100s000) session, Configurator or Product Configurator for MTO, BaanERP will move to the appropriate configurator. This can either be the Baan Configurator (CF), or Product Configuration (PCF). When both are selected, in the Generic Item Template Relationships (cftpl1100m000) session, you can select the configurator to be used for each generic item. As a result, the product variant is shown in the project budget. 5 Carry out the same steps, starting at step 4, of the Standard item procedure through budget lines in project budget section earlier in this chapter. Generic Item Material Budget Line Configure item CF CF or PCF applicable PCF CF Procedure (See detail flow Manufacuring) PCF Procedure (See detail flow Manufacturing) Configured (generic) Item Make Customized (See details in previous figure 2) Figure 4 Flow generic item 3-12

23 Customized (existing) item When an existing customized item is used, the PCS project has already been defined. Actions Project: 1 Define a project in the Maintain Projects (tppdm6500m000) session; you can use an element or activity budget. You can link a default project warehouse to either the project or in more detail, to the element or activity. In this way, the project warehouse will be set to the Generated PRP Warehouse Orders. This procedure assumes you are able to maintain the remaining parts of the project definition. However, you must change the project status to Active when you carry out step 5. 2 Define activity, Charge Breakdown Structure, and/or elements, depending on the types of budget you want to use. You can link a default project warehouse to the element or activity. In this way, the project warehouse will be used when Generating PRP Warehouse Orders. This procedure assumes you have set up the element and/or activity structure. However, you must change the element and/or activity status to Actual when you carry out step 5. 3 Start the Element Budget (tpptc1810m000) session or the Activity Budget (tpptc2810m000) session and insert a Customized item. Because the customized item already has a PCS code, you must insert this item code in the first field instead of the second field. As a result, BaanERP will automatically create a link with the existing PCS project. This is visible in the Project-PCS Relationship (tppdm6150m000) session. 4 Carry out the same steps, starting at step 5, of the Standard item procedure through budget lines in project budget section earlier in this chapter. Customized Item Material Budget Line Project-PCS relationship Figure 5 Flow customized item 3-13

24 Multiple parts of (standard) manufactured item You have previously read, the procedures to receive the end item in BaanProject. In many project industries, the end item is not produced at the plant site, but is produced at the customer site. For these situations, you can create a PCS integration to receive the components instead of the end item. In the following example, the flow for a standard manufactured item, which will be customized in Project, is described. Instead of selecting the main level item, the lower level items of the bill of material are selected. This means that items B and C will be delivered at the project site and will be assembled at a later date. The budget lines will be created for items A, B, and C. In this situation, the main item must be of the Manufactured type and the Order Policy must be To Order. Lower Level parts however, can also be Purchased. In the following figure, the main item A, including the BOM, already exists in BaanERP. A Manufactured B Manufactured C Purchased B1 Purchased B2 Purchased Figure 6 Bill of Material 3-14

25 Actions Project: 1 Define a project in the Maintain Projects (tppdm6100m000) session; you can use an element or an activity budget, and link it to a project warehouse. The enterprise unit of the project must be the same as the enterprise unit of the project warehouse. 2 For this procedure, creating a project structure is not applicable. However, you must change the status of the Element Budget (tpptc1810m000) session or the status of the Activity Budget (tpptc2810m000) session to Actual. You must change the project status to Active. You can change these statuses after the budget is complete. 3 Start the Element Budget (tpptc1810m000) session or the Activity Budget (tpptc2810m000) session and insert the Manufactured item A. The remaining items will be inserted later as they will be customized in Manufacturing. This action is only to create a PCS project and the link with Project and PCS. 4 Select item A, and click Make Customized. BaanERP will prompt to perform a cost price calculation for this customized item. Click Yes to calculate the cost price. This cost price can differ from the standard cost price. Depending on the number of items, the costs of setup times for example, can vary. After the calculation, BaanERP will prompt you to link the PCS Project to the current Baan Project. Click Yes. As a result, you will have a customized item that is copied from the standard item. Only the top level has been copied. BaanERP will add the PCS code in front of the item code and will automatically create a PCS project. An alternative approach is to configure an item and skip the next step. 5 The shortest procedure to execute this PCS procedure is by using the Copy Standard Product Structure to Customized Structure (tipcs2230m000) session. To copy the Standard item A and structure to the Customized item A with structure, use the following options: Customized Item: Select the item number you just have created. Copy Method for Prod. Structure: Select Multilevel. Copy Method for Items: Select To-Order items. Copy E-item Relationships: Clear. Generate New Item Codes when Customized Item exists: Clear. Ask Before Generate New Code: Clear. This will result in a Customized item A including structure. There are two options to order the components of item A: To add the components to the budget. Copy the planned warehouse orders during the requirements planning. 3-15

26 The project and plan data for the item must have been defined. To add the components to the budget. On the material budget lines, delete the original item line of item A. You must use this method to avoid manual procedures in Manufacturing such as, creating PCS projects and so on. Insert customized item B and C. Customized item C is a purchase item. Therefore, BaanERP will create a warehouse order for the item at requirements planning, because it is a customized item. Carry out the same steps as described in the procedure for standard item in step 4, Generate Control Data. To copy planned warehouse orders during the requirements planning: Start the Generate Planned PRP Orders (tppss6200m000) session to create a Planned PRP Warehouse Order. Start the Planned PRP Warehouse Orders (tppss6515m000) session. Select the order for item A and copy this record two times, to item B and item C. Ignore reschedule messages for these items. The scheduling update for orders is a manual process. Click Confirm to confirm the orders. You do not have to use the Confirm Planned PRP Warehouse Orders (tppss6225m000) session. 6 Carry out the same steps, starting at step 8, of the Standard item procedure through budget lines in project budget section earlier in this chapter. 3-16

27 Standard Manuf. Main Item Material Budget Line Make Customized (See detail flow) Copy Standard Product Structure (Manufacturing) Customized Item Structure Budget Lines Order Components by budget lines or during PRP PRP Delete Main Item, Insert Sub Items Generate Planned PRP Warehouse Orders Generate Control Data (etc.) Copy main item order to components Confirm Planned PRP Warehouse Orders (etc.) Figure 7 Flow ordering components 3-17

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