Академический Документы
Профессиональный Документы
Культура Документы
2011
V6.1
Training Course
OP203: Fundamentals Manufacturing
/ © Sage 2010
Timing and Breaks
Because our brains are not computers, we will have a break
every hour and quarter, here is the daily schedule :
If you wish to meet someone, you can inform him or her about
the above schedule.
Distribution
Contracts (Purchasing and Sales) Distribution and
CB 101 – 102 Loan Orders Inventory
Introduction & Packaging & Shipment Preparation Purchasing Subcontracts
Purchasing Signature Management Pre-Allocations (Pegging Function)
Functional Overview
Sales and Purchasing Prepayments
(3 days) TEC102 Radio Terminals
Sales Reps and Commissions
Development Sourcing: RFQs, Responses
Carrier Management
(4 days) Inter-Site and Intercompany Transactions Manufacturing (5 days)
Invoice Elements (Purchasing & Sales) Configurator
Kits, Options & Variants
Weighing
Price List Management (Advanced)
TEC103 Manufacturing (4 days) Optimisation ILOG
Course Map
4 Title of the Presentation
Objectives
Tracking
Closing
Costing
Preamble
Work Orders
Common data
Tracking
Appendix
7 / © Sage 2010 OP203: Fundamentals Manufacturing
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
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
1 PRODUCT PRODUCT
1 • S&OP*, Forecast, MPS*…
Customer
Lead Time
Variety
1
ETO
Project
2
Job shop MTO
Intermittent
ATO 3
Batch
Repetitive FTO
4
Line
Continuous MTS
Volume
20 / © Sage 2010 OP203: Fundamentals Manufacturing
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
CIM
Data base
Improvement
management
Manufacturing
Common Demand Tracking Feedback
data • MPS-MRP
• X3 • Workbenches • Material • Costing
• Product Forecasts tracking • Reports
categories • Analysis
entries
(Materials & • Operation • Comparisons
• Products • X3 Sales tracking
Loads)
• Product site order • Production
• Purchases
• Bill of • Releases
tracking
Material
• Modifications
• Routing
• Prints
Routing
BOM*
Product
Work Orders Stock Change Production Tracking Work Order Close WIP
(GESMFG) (GESSCS) (GESMTK) (FUNMCLOSE) Finalization
(FUNWIPMFC)
Time
Tracking
(FUNBENCHO)
Product
Demand
Supply
Order status
Release
S&OP RRP*
Category Work centers
Product
MPS RCCP* Routing
Bill of Material
PAC Input Output
control
Demand
Load
Supply
* RRP : Resource Requirements Planning
Capacity
drives
* RCCP : Rough Cut Capacity Planning
* CRP : Capacity Requirements Planning constraints
33 / © Sage 2010 OP203: Fundamentals Manufacturing
Exercise 2.3 – Demand-Supply balance
inside the work order
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
Product – category
Rules Rules
Site
Product Product- Product-
data Site data Site data
Default value
Product-Site
Product
Product Product-
data Site data
The order management strategy: the customer, its order number and the
project designation are kept on the orders
A default location can be If the document and/or The entry can trigger an
proposed during an the product definition analysis request
entry. The description don’t force the Q status,
(area) given by the a default status can be
column aims to make it proposed per entry
easy to find the good transaction
location type and/or the
location in the product
site
Management
rules
Lot entry
Lot by default
If the product is lot
A sales order or a work
managed we can control
order number can be
if the lot exists in the
used as the lot number
database
Issue flows
tab
Issue rule
Management rules
Stock lines determination
rules applied during Each movement type can
issues be customized
Planning Manufacturing
Reordering
Parameters
Depending on the
planner managing Depending on the
decisions, different reordering choices some
reordering rules can be data here are mandatory
set and adjusted
Miscellaneous Use
Identification
tab
Image
Inventory parameters
Recontrol/Expiration
Inquiries
Functions
Costing
Quality
Sampling
Planning
Lead times
Reordering
Re-planning
Entries
Issues
Entry data
Calculated data
Routings
Parameter definition
Cost tab
Cost calculation
Manual entry for
components unless
calculation process is Unit price
launched using last price AVC, Last receipt cost &
for example. Calculated standard cost are
for produced goods. broken down into details
The Routing
Head of routing
Header tab
Routings tab
Scheduling
Provisional Routing
and WO CRP
cost roll up
(MRP)
Load &
scheduling
calculation
during releases
62 / © Sage 2010
Exercise 3.5 – Routing Set Up
Interoperation time
Load
Cost
Scheduling
Parent-component relationship
Parent product
Where-used Link
B Component
The levels
Level 0
B C Level 1 G H
B C
D Level 2 B
Assembly A
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
Action Vision
WO Shop packet
Suggestion (MRP, MPS, Reordering point, or periods)
DEMAND SUPPLY
PORDERQ
Purchase
SORDERQ orders
SOF POF
Sales
orders
MFGITM
MFGMAT Work Orders Produced
Material
goods
Release
product
Parent product
WOF WOP WOS
of the BOM
By-
product
Component of
BWF BWP BWS
the BOM
Component
Component of MWF MWP MWS
the BOM
78 / © Sage 2010
OP203: Fundamentals Manufacturing
Exercise 4.1 – Forecasts
WO Transaction
Work Order Suggested
• From MRP & MPS Work Order Planned
• From ROP Work Order Firm
Work Order Planned
Direct release
Data filtering
Resource Orders
Being
Optimized
Optimized
Possibly
suspended
Lot Management
General parameter LOTMGT
In WOP
planning
LOT
No (stock See Work order entry transaction if lot entered and entry
rules flow, movement type in the category: Lot entry and lot by
applied) default + Lot sequence number (Controls tab, product)
Scrap
X3 formula Qr = Qn (1 + scrap)
Qn
APICS formula Qr =
(1 – scrap)
If Scrap factor = 50 %
Case 1 (ERP X3) : Qr = 150
Case 2 (APICS) : Qr = 200
Lead time
Operation scheduling
Schedule
Not scheduled Scheduled Reschedule Optimized
Mark to reschedule
26/MM/YY 30/MM/YY
Routing operation 0
Operation LT 0
26/MM/YY 30/MM/YY
Routing operation 0
Operation LT 1
26/MM/YY 30/MM/YY
Routing operation 40
Operation LT 0
Operation scheduling
Operation Next Scheduling
operation
Op. 10 Op. 20 Overlapping
Op. 50
Date of SOF
process
WOS
Manufacturing
start date Backward scheduling by
overshooted default
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
Load determination
Understanding the Load
Load & Infinite Schedule
General parameter:
Default weekly structure STO/SCH
Work Order PLNTWD
Unavailable FR10
Work Centers
Weekly
SC1
Structures
WC No. of
2
resources
Capacity
variations
Operation 40 hours in
on 1.4 days
WO3 No. res =4
109 / © Sage 2010
OP203: Fundamentals Manufacturing
Understanding the Load
Load & Infinite Schedule
Operation 40 hours in
on 1.4 days
WO3 No. res =4
110 / © Sage 2010
OP203: Fundamentals Manufacturing
Exercise 5.1 – Work Order generation,
preparation for firm load
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
Updating authorization
Understanding the possible actions Modifying components
inside the work order Modifying operations
Planning regeneration
Understanding tools to modify work
Available functions
orders
Modifying components
Exclude/reactivate
Add
Replace
Modifying operations
Exclude/reactivate
Add
Replacement
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
Tracking definition
Understanding the principles Personnel IDs
The single WO tracking
Time tracking
Production tracking
Understanding the workbench tracking
Material tracking
Reintegration
Tracking
•Material
tracking
Work Order
• Pending
Transaction •Operation
• Printing tracking
• In progress
• Completed
•Production
tracking
•Back flush
Track Immediate materials •All
•Closed
Not closed •All
•Reject Message
Miscellaneous •Personnel ID Tracking
•Message
•Material
tracking
Time
Tracking
Material Tracking
Time
Tracking
Material
Tracking
Plan
Op No Milestone
10 No
20 Normal tracking
30 No
40 No
50 Range
Unit Status
Location;
Completed Tot. Achieved Misc.
Lot & Sublot;
Quantity Quantity Stock
Misc. Serial Number;
• operations (start/end) Info.
Stock Info. …
• material tracking mgt Quantity
• status of closure Filter tracked
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
Line Status
Tracking Close
Pending In Closed
progress
Product WO
Time Materials
Released Completed
Close
Close
Close
Close
Allocation
Load WOF
MWF
WIP
139 / © Sage 2010 OP203: Fundamentals Manufacturing
3 types of Cost
Raw 2 Opé 2
Raw 2 Opé 2
? Raw 3
Raw 2 Opé 2
Raw 3
TC/COS GPA/COS
CLCSTD*MAT CLCSTDRAT
GPA/COS GPA/COS
SCAMAJ EFFCSTUSE
GPA/COS
OVECOLSTD
Release Provisional
Actual cost
Material cost
Labour cost
Machine cost
Sub-contracting cost
(Theoretical) Provisional
Release Provisional
GPA/COS TC/COS
CLCWOCAUT VLTSEMEXT
Actual cost
Release Provisional
Actual cost
GPA/COS
MFCRATCPL
Product site, valuation
method (Cost tab), see first
value “Valuation”
GPA/COS
OPRRATE
GPA/COS
OVECOLMFC
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
Machine Machine
Labour Labour
Overhead Overhead
Subcontract Subcontract
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
Chapter Contents
CD
BOC TC/BOM
Activity Code General Parameter BOMLEV
CD
BOD TC/BOM
BOMSTE
CD
BOW
M
UML
I
LOT
M GPA/ROU
Activity Code MFO General Parameter DEFWORTYP
GPA/ROU
ROUSTE
GPA/MIS
OPEEFFAPP
GPA/MIS
WSTEFFINH
GPA/WOM
Activity Code M General Parameter CUMMAT
MFM
M GPA/CTL
MFI DOSFAB
GPA/MIS
M
LOTMGT
MFO
GPA/WOM GPA/MIS
RELUPD GRGENPLN
General Parameters
STO/MIS STO/SCH
MFGMTSNUM GPLNFLT
Work Order
STO/SCH
GPLNHOR
ACH/AUZ
BUYFLT
Tracking
GPA/CTL GPA/CTL
CTLALL CTLFICTEC
GPA/CTL GPA/CTL
MTKALLMGT CTLOPEPRE
GPA/CTL
DOSFAB