QAD 2008 Enterprise Edition User Guide: Manufacturing
Contents
1. 00 0002 eee 259 Milestone and Non Milestone Operations 4 260 Before Tracing Subcontracted WIP Material 260 Lot Sizing Restrictions 0 0 0 cee cee eee 260 Inventory Lot Quantity Issuing Restrictions 261 Inventory References 2 0 0 cece eee eee 262 Lot Splitting and Combining 0 00 e eee eee 262 Custom Lot Serial Number Formats 00000 000 263 AQAD Contents Xi Maintaining Accurate System Configuration Information 263 Setting Up WIP Lot Trace 1 0 eee eee 264 Defining Control Program Settings 00 0 0 0008 265 Registering Routing Exceptions 0 00 eee eee eee eee 268 Registering BOM Exceptions 0 0 0 2 eee eee eee eee 272 Working with WIP Lot Trace seeeeeeeeee eee nee 274 Using WLT Data Collection Frames 0 00000 e eee 275 Using WLT with Work Orders eese eee 284 Using WLT with Advanced Repetitive 00 00008 291 Using WLT with Purchasing 0 2 0 0 eee eee eee eee 294 Using WLT with Repetitive 20 0 0 0 eee eee eee 298 Reporting WIP Lot Trace Data 0 0 2 eee ee 299 Chapter 11 Quality Management sse 303 Introduction ciu eet UR ce egre eder Unde ues 304 Setting Up Quality Management eeeeee eee 305 Setting Up Control Programs 0 0 eee eee eee2. 0 0 0 enuen rarr 38 Manufacturing Lead Time 20 0 0 eee ee eee ee 39 Subcontract Operations 0 0 ee cece eee ae 40 Yield i025 si 500d web ER tied ewiwaddengude hewg hd tdvea ses 41 Yield Percent i eris tunt ee Ee UR e e ob ua 41 Operation Based Yield 0 0 0 eee eee eee 42 FAQAD Contents v Chapter 4 Formulas and Processes 45 Introduction suisses pr ee ees asad ERA CR ORE Sea Vea qp d ae 46 Defining Formulas leeeeeeeeee eh 47 D tining Processes iiber ebb Dr cR a ek A ERR E CI 50 Process Formula Maintenance 0 0 0 cece eee eee 51 Chapter 5 Co products and By products 53 Intr duction ses sira ess aha teh admis ed tees has COH RR COO CRECODAG de 54 OVERVIEW ices ese detec e oe oe e descen e n se Roe ets t pea he ee 55 More About Co products and By products 00 57 Co product By product Workflow eeeeeeeeeee 58 Setting Up a Co By product Operation sssssa susana rrr 58 Setting Up Mix Variance Accounts 0 000 cece eee eee 59 Setting Up Sites and Locations for the Base Process 59 Setting Up Work Centers 20 0 0 ccc eens 60 Setting Up Product Lines 60 Setting Up Item Status Codes for the Base Process 60 Setting Up the Base Process Item 0 0 0c ee ee eee 60 Setting Up Items for Co products and By products 61
3. One for sample size One for quantity accepted One for quantity rejected Item specifications can be maintained in the Product Change Control module The effective date is used to phase in changes managed with product change orders Setting Up Procedures A quality procedure consists of one or more operations generally inspection or testing operations linked to a work center Define quality procedures in Procedure Maintenance 19 2 1 Quality procedures are used by quality orders in the same way routings are used by work orders Quality Management 309 Fig 11 5 zx Procedure Quality Order Maintenance Go To Actions Maintenance 19 2 1 Quality Order 1003 Batch 5 Item Number WLT18 P1 WIP Lot Std Rep Unit of Measure EA Parent 1 Type I Site 10000 Auto Issue V Quantity Pending 100 0 Start Date 02 27 2007 Quantity Accepted 0 0 Release Date 02 27 2007 Quantity Rejected 0 0 Due Date 02 27 2007 Effective Date 02 27 2007 Status c Procedure test P PO Job Project Remarks Operation lead time indicates the time stated in decimal hours this test operation normally takes Operation time is independent of the number of units being tested Make sure you enter it consistently as either time per unit or time per test batch Note There is no integration between quality procedures and capacity requirements plan CRP You can link each operation of a procedure to one or more items in the Procedu
4. Subcontract Shipping Control v X Subcontract Shipping Control Go To Actions Unassigned Suppliers v Manual Shipper Update v Scrap Unreturned Material Unassigned Suppliers Indicate if you want to restrict subcontractors to those specifically assigned to a routing operation when you create the subcontract shipper No the default You can specify only subcontractors associated with the routing and operation when creating the subcontract shipper Yes You can specify subcontractors not associated with the routing and operation when creating the subcontract shipper Note You specify scheduled orders for a specific routing and operation in Subcontract MRP 46 Maint 5 5 1 21 You specify discrete purchase orders for a specific routing and operation through Subcontract Routing Op PO Maint 5 11 Advanced Repetitive 209 When you create a subcontract shipper you can specify a cumulative ID The system populates subcontract shipper fields with the subcontractor data associated with the ID To be able to associate a subcontract shipper with a different subcontractor set this field to Yes Example Your company uses three different subcontractors to paint item A bicycle frames subcontract suppliers A B and C Work order 20 specifies that item A is painted red In Subcontract Routing Op PO Maint you specify the subcontract PAINT operation and routing for subcontract supplier A and B only If y
5. To scrap the quantity manually set Scrap Unreturned Material in Subcontract Shipping Control 18 22 5 24 to No Close Sub Shipper in the Subcontract Shippers frame to Yes Scrap the short amount using the scrap program of your choice FAQAD Advanced Repetitive 223 Scrapping Items through Subcontract Scrap Maintenance Use Subcontract Scrap Maintenance 18 22 5 13 to register a scrap transaction for subcontracted material against one or more subcontract shippers This program Registers a scrap transaction in Advanced Repetitive records Adjusts the scrap quantity on the subcontract shipper Removes quantities from the input and output queues of a subcontract operation To register scrap through Subcontract Scrap Maintenance use the following procedure 1 Enter selection criteria in the header including the item supplier site ship date subcontract shipper ID and cumulative ID Note If the cumulative ID you entered expired but the subcontract shipper is not complete the system may have replaced the cumulative ID on the purchase order When this happens the system finds the subcontract PO lines for the supplier you entered then matches the item number on the new cumulative ID to the item number on the expired cumulative ID to determine which shipper to display 2 Select a subcontract shipper from the display in the Subcontract Shippers frame Information about the subcontract shipper displays in th
6. Work Order Accounting Close 16 21 When you run Work Order Accounting Close the following occurs Co product costs are re averaged by taking any remaining positive or negative WIP costs and allocating them to the co products If additional costs are recorded for a work order after costs are allocated the remaining costs can be reallocated by reopening the closed work order applying the transaction and closing it again General ledger GL and current costs are updated Co products and By products 73 Some typical steps for calculating average GL costs and average current costs for co products follow 1 Define the average cost allocation methods in Average Cost Method Maintenance 15 12 5 2 Verify that the following are correct Co product by product definitions Prices for co products if allocation method involves price By product costs Base process batch size UM of the BOM Formula code for the base process equals the item UM for the base process Site setup for cost sets GL Cost Set and Current Cost Set Unit of measure conversions from base process to co products and by products Defining the Average Cost Allocation Methods Define the average cost allocation methods using Average Cost Method Maintenance 15 12 5 The system provides three methods for allocating costs from a joint order set to co products Price Receipt Quantity Receipt Quantity and Price If other methods are needed users
7. FAQAD 160 User Guide QAD Manufacturing b For more information see Milestone and Non Milestone Operations on page 167 FAQAD For example if there is a yield of less than 100 at an operation this will cause the overall cost to manufacture to increase since not all the material produced is expected to be good If No then 100 is substituted for the Yield field Zero Balance WIP This field determines how queue quantities at non milestone operations are affected when production is reported at subsequent operations This setting affects Quantities processed in Backflush Transaction 18 22 13 Subcontract shipper issues in Sub Shipper Issue 18 22 5 11 Receipts from subcontract shippers or purchase orders using PO Shipper Receipt 5 5 5 11 or Purchase Order Receipts 5 13 1 When Zero Balance WIP is Yes the system does the following after transferring the item quantity processed issued or received from the input queue of the reporting operation and when needed the queues of previous non milestone operations Moves any leftover quantities from previous non milestone operation queues to the input queue of the non milestone operation that directly follows the previous milestone operation Sets all other queue quantities to zero for previous non milestone operations up to the preceding milestone operation When Zero Balance WIP is No leftover quantities remain in non milestone operation queues
8. Forecasting Master Schedule Planning 347 In these cases it is impossible to accurately forecast all of these possible combinations for master production scheduling purposes Instead you can forecast items at the family item and planning or option item levels Multilevel master scheduling enables you to perform this type of forecasting for planning purposes Planning Bills You can establish the relationship between family level items and component items by defining planning bills in Product Structure Maintenance 13 5 or Formula Maintenance 15 5 These are identified with a structure type of P planning Usually the top level item of a multilevel master schedule product structure or planning bill represents the entire group or family of products that can be configured from a set of available models and options Family items are never manufactured or stocked You must define family items with a Pur Mfg code of Family F in Item Master Maintenance 1 4 1 Item Planning Maintenance 1 4 7 or Item Site Planning Maintenance 1 4 17 Components of the family item in the planning bill can be any type of item manufactured configured or another family item A planning bill also contains a forecast percentage The forecast percentage is the probability that a component of the family level or parent item will be required given the requirements for its parent Components with structure code Planning consume the forecast for their
9. 50 100 112 0 5 56 cus NR 1002 Pulp 112 30 100 112 0 3 2 33 6 MAX Method 1003 Seeds 112 10 100 112 0 1 11 2 Based on these expected quantities mix variance calculations are as shown in Table 5 14 Table 5 14 Order ID Product Mix Variance Calculation Sample Mix 1001 Orange Juice 56 56 1 50 0 1 50 0 00 efto 1002 Pulp 33 6 28 0 50 5 6 0 50 2 80 MAX Method 1003 Seeds 11 2 15 0 60 3 8 0 60 2 28 When the Maximum method is used the co product that consumed the largest quantity of the base process in proportion to the quantity ordered always has a zero mix variance This is because the base process quantity complete is derived directly from the actual quantity complete for that co product The Maximum and Minimum methods are most appropriate when a particular co product in the co by product structure is considered the primary co product for the base process A primary co product typically drives demand and determines the rate of production for the base process Examples of production processes that involve a primary co product include sheet metal stamping and injection molding Minimum If Quantity Complete Method is set to MIN in the co by product structure the system performs the same calculations for each co product in the joint order set as when Quantity Complete Method is MAX However the calculation that yields the lowest rather than the highest result is
10. A supply order was created for a quantity greater than the maximum quantity set in the item planning data Scheduled supply order receipt is past the due date Unsatisfied material requirement exists inside the planning time fence for the item MRP will not create planned orders within the time fence You should either manually schedule and expedite orders to fill this demand or delay fulfillment of the requirement that created the demand A shipment for an intersite request item is due Action should be taken at the source site to ensure that the order is received on time A shipment for an intersite request item is past due You should either delay the orders that created the requirement for the item or expedite them when the item does arrive Material Requirements Planning 375 Message Meaning No Source Of Supply A valid source network is not available for the date a DRP item is required Either the item or item site planning data does not reference a source network or the source network is not effective on that date Planned Order Count An item site combination generated the maximum number Exceeds Maximum of planned orders MRP currently cuts off the creation of orders for an item site combination at 1000 Calculation for other items continues This prevents runaway calculations caused by for example an incorrect item order quantity Planned Orders MRP generates planned orders to satisfy net requirements for items wit
11. In this case the table simply indicates one or more typical programs associated with the transaction and is not intended to be a complete list Shop Floor Control Transaction Type Description Program BACKFLSH Advanced Repetitive labor and Backflush Transaction 18 22 13 material usage CLOSE Operation closed Cumulative Order Close 18 22 10 DOWN Non productive labor reported Labor Feedback by Work Order for Shop Floor Control functions 16 20 1 DOWNTIME Downtime hours reported for Repetitive Labor Transaction 18 14 Repetitive and Advanced Down Time Transaction 18 22 20 Repetitive functions EXPENSE Expense consumed for Customer Call Activity Recording 11 1 1 13 Services functions Project Activity Recording 10 5 13 FLOORSTK _ Floor stock inventory expense Post Accumulated Usage Variance posted at order close 18 22 9 LABOR Labor hours reported for Repetitive Labor Transaction 18 14 Repetitive Advanced Repetitive Run Labor Transaction 18 22 14 and Customer Services functions Call Activity Recording 11 1 1 13 Project Activity Recording 10 5 13 MOVE Moved to next operation Labor Feedback by Work Order 16 20 1 MUV CMP Material usage variance posted Post Accumulated Usage Variance for component usage variance at 18 22 9 order close MUV WIP Material usage variance posted Post Accumulated Usage Variance for WIP material scrap usage 1
12. Processing a Subcontract Operation Processing a subcontract operation when using WIP Lot Trace and Advanced Repetitive adds a few minor steps to the subcontract procedure Note This procedure assumes that you have already backflushed all operations previous to the subcontract operation 1 Create a scheduled order in Supplier Scheduled Order Maintenance 5 5 1 13 Specify the appropriate cumulative work order ID and subcontract operation Note The system automatically populates the work order ID and operation fields when it creates a cumulative ID through any Advanced Repetitive transaction 2 Createa subcontract shipper in Sub Shipper Maintenance 18 22 5 5 a Use the parent item site as the ship from and the supplier as the ship to b Use the cumulative order ID and subcontract operation used on the scheduled order WIP Lot Trace 297 c Specify the WIP lot serials and quantity being sent to the P See page 283 subcontractor in the WLT WIP Lot Move Data frame Select Help to display a list of WIP lot serials produced at the previous operation 3 Print the subcontract shipper using Sub Shipper Print 18 22 5 9 The WIP lot serials entered in the WIP Lot Move Data frame display as Lots Shipped 4 Confirm the subcontract shipper using Sub Shipper Issue 18 22 5 11 This moves the indicated WIP lot serials from the output queue of the previous operation to the input queue of the indicated operation 5 Receive the schedule
13. Retesh gt Purchase Order hers Number C21 1Component 7 Ta GT T Comporert d i ho To Cota 7 telema Buyer Te os Lf Schedule Type 5 5 Sucgles Parning Sch AcweMet Ache vl iot Opt T 1 By Sho To Supeka em PO 2 By hens She To Sgen PO y FO Den Displaying Components Your purchased component may not display in Component Check by Item Work Order Browse When this happens it is typically because 1 The browse is driven by work order demand records where an exploded BOM exists An item record only displays when it is created by an exploded BOM record If the purchased part demand is driven directly from a sales order forecast safety stock and so on the item record does not display in the list If the item belongs to a BOM of a manufactured item but still does not display in the list it is because you need to run CRP to explode the P lanned status work order to which this item belongs Run CRP for planned orders to generate the exploded BOM Examples You can anticipate when a material shortage typically occurs in your production cycle to determine if your supply meets future demand For example if a material shortage typically occurs two to three days before a standard supplier delivery on the first of every month you can factor in this anticipated shortage and view incoming supply to determine if the demand can be met Repetitive 247 Since you can view both planned and confirmed orders f
14. 0 0000 e eae 332 Generating Reports 0 0 eee eee eee nee 335 Making Forecast Data Visible to MRP esses 336 Deleting and Archiving Forecasting Detail Records 338 Maintaining Forecasts Outside of Forecast Simulation 338 Consuming Forecasts es certesa rwr pe Wa Aa CREE DUET ES 339 Sales Order Demand ios eise rapae taa noah EESE EER eee 340 Net Forecast Calculation 0 0 0 cee eee eee 340 Forward and Backward Forecast Consumption 341 Creating Master Production Schedules 0 0 0 0 cece ee eee 343 Master Scheduled Items 0 0 0 0 0c eee eee eee 343 Approaches to Master Scheduling eel 343 Available to Promise lsseee 345 Multilevel Master Scheduling 0 0 0 ce ee eee eee 346 Maintaining Master Schedule Orders 00 004 349 Verifying Capacity for Master Schedules 0 351 Master Scheduling for Seasonality 0 00 c eee eee 351 Generating Master Schedule Reports 2 00 0 5 353 Chapter 13 Material Requirements Planning 355 Introduction 332 ates rro kad beg repa d eb dea a pesi te Re 356 MRP and Sites ei csse ee e Ee eR Rede ba ebbe 356 Sources of Demand and Supply 0 0 0 e eee eee ee 356 Setting Up MRP ia ec cea cee e See eee eee bina Pe eee s 357 MRP Control 52 t Rer ecd e x Re a ac suena 358 Item Planning D
15. FAQAD 216 User Guide QAD Manufacturing Backflushes components used in the subcontract items If you use PO Shipper Maintenance you can record the subcontract receipt and take time to compare the actual received items against the receipt quantity Use PO Shipper Receipt 5 5 5 11 and 5 13 20 to update inventory and the GL after you manually verify received subcontract items and quantities with PO Shipper Maintenance Note PO Fiscal Receiving 5 13 16 functions similarly to PO Shipper Maintenance however fiscal receipts are typically for inventory as opposed to receipts for subcontracted services Therefore subcontract shipping receipt functionality as described in this section does not apply to PO Fiscal Receiving Connecting Shippers to Received Items gt For more When receiving subcontracted items you can connect subcontract information on shippers to the receipt for more subcontract visibility connecting shippers see page 209 When you connect a subcontract shipper ID to purchase order lines you are receiving against you can also See Moving Place the items into finished goods automatically if the subcontract Finished operation is the last operation and the items are lot or serial Subcontract Items to controlled I tory page 224 T Note If WIP item components are lot serial controlled you must use the Advanced Repetitive Move Transaction 18 22 19 to record the WIP item placement into inve
16. Most user documentation is available in two formats Portable document format PDF files can be downloaded from the QAD Web site to your computer You can view and print them with the free Adobe Acrobat Reader HTML files let you view user documentation through your Web browser and use search tools for easily locating topics of interest Conventions Screen Illustrations System functions are available in a feature rich NET based graphical user interface UI a subset of functions can be used in a simplified character interface All screenshots in the documentation show the NET UL Navigation in the two UIs is not the same The user guide text follows the navigation model of the NET UI for moving from one screen to the next In the character interface the Progress status line at the bottom of a program window lists the main UI specific keyboard commands used in that program In the NET UI alternate commands are listed in the Actions menu For complete keyboard command summaries for UI navigation refer to the appropriate chapters of User Guide QAD User Interfaces Typographic This document uses the text or typographic conventions listed in the following table If you see It means monospaced text A command or file name italicized A variable name for a value you enter as part of an operating monospaced text system command for example YourCDROMDir FAQAD 4 User Guide QAD Manufactu
17. Once a formula has been defined for a particular product that product can produce a higher level product This is typical of a master batch or an oven heat which processes other items When discrete components are issued such as packaging and labels closing the process batch work order and issuing the batch to a discrete packaging work order can be useful The system offers process discrete and model option work orders or paperless repetitive scheduling in a single environment You can backflush components for any of these types of production scheduling A formula sometimes called a recipe defines the ingredients for a manufactured item Use Formula Maintenance 15 5 to define formulas The system automatically assigns the item number to the BOM Fig 4 2 Tx Formula Formula Maintenance Go To Actions Maintenance 15 5 Parent Item BRACKBCT4 None 00 Batch Size 1 EA Description Bumper Rack for BCT4 Component Item APS 1111 Component 1111 Rev Reference Effective Date Ta Quantity per Batch fy EA Scrap 0 00 m Lead Time Offset Operation Quantity Type o o Batch Percent Structure Type Sequence Number Start Effective M Forecast Percent 100 0096 End Effective v Option Group P Remarks Process P FAQAD 48 User Guide QAD Manufacturing b See page 17 FAQAD This program is very similar to Product Structure Maintenance Only additional fields are described here Bat
18. Setting Up a Co By product Structure 0 0000 62 Setting Up Structures for Recyclable By products 64 Setting Up Unit of Measure Conversion Factors 66 Setting Up Alternate Base Processes 00000 c eee ee eee 67 Setting Up Alternate Base Process Routings 67 Setting Up Definitions for Valid Substitute Items 68 Calculating Costs and Lead Times 0 00 e cee eee 69 Allocating Costs to Co products 0 0 0 0c e eee eee eee 69 Entering By product Costs 71 Freezing By product Costs 1 0 0 cece eee ee eee ee 71 Rolling Up Costs 0 0 eee III 72 Calculating Average Costs for Co products 2 0 72 Defining the Average Cost Allocation Methods 73 Average Cost Accounting 0 0 cece eee eee es 75 Rolling Up Lead Times ssseeeeeee eee 76 vi User Guide QAD Manufacturing Reviewing Product Costs 0 0 eee eee ene TI MRP for Co products By products seeeee eee TI Planning for By products 0 cece eee eens TI Planning for Co products 0 0 0 eee eee 77 Planning for Base Processes 0 0 0 e eee eee eee eens 79 Reviewing Updating and Reporting Action Messages 79 Approving Planned Work Orders lees 80 Creating Planned Order Reports llleleeeeeeeeess 80 Creating MRP Summary Reports 0 0 e eee
19. Standard Operation Work Center 100 01 Assembly Machine Description Machines per Operation 2 Milestone Operation 7 Overlap Units 0 Subcontract LT 0 Queue Time 2 0 Setup Crew 2 00 Wait Time 1 0 Run Crew 5 00 Setup Time 0 0 Yield Percent 100 0096 Run Time Batch Qty 0 0 Tool Code Move Time 0 0 Supplier Start Date Subcontract Cost 0 00 End Date Comments Batch Quantity A system maintained field recording the normal batch quantity for an item If the formula was entered in Formula Maintenance Batch Quantity defaults from the item master Otherwise it defaults from Formula Code Maintenance Use Batch Quantity Change 15 9 to change the value Ingredient quantity per and process operation run times are stated in terms of this batch quantity Run Time Batch Qty Enter the process operation run time in terms of the batch quantity for the item To save data entry time when defining processes for items that share similar operations or when creating alternates copy an existing definition record with Process Definition Copy 15 16 Then add change or delete operations as needed Formulas and Processes 51 Process Formula Maintenance Process Formula Maintenance 15 18 lets you enter formula batch process and co product by product information from a single menu program This is particularly useful when you are setting up processing for co products by products Process Formula Maintenance
20. Use it to trace component WIP material and finished goods based on parent items product structures and routings WIP Lot Trace 253 WIP Lot Trace and Regulatory Attributes The WIP Lot Trace module and the Regulatory Attributes module trace P See User Guide material at different stages in the manufacturing process gan Master With Regulatory Attributes lot control you trace inventory and the consumption of component material lots into finished material lots With WLT you trace consumption of component material lots into WIP material lots and the consumption of WIP and additional component material lots into finished material lots The two modules can work together or individually Performance is seamless when using one or both of these related but different modules Each module requires separate setup and operation When using automatic lot numbering features of Regulatory Attributes the finished item lot serial number is automatically created when the item is moved into finished item inventory Automatic lot numbering occurs even if you are using WLT If you are not using automatic lot numbering you can assign a new lot serial number to the finished item or use the WIP lot serial for the finished item Features Using the WIP Lot Trace module you can Trace lot and serial numbers of WIP material throughout the manufacturing process including WIP material processed by multiple subcontractors Create flexible registrati
21. Work Center Capacity CRP uses work center capacity when evaluating work center load It is the total number of hours the work center is available to do work Capacity varies with the work center calendar or shop calendar and the number of machines or people in the work center The formula is Work Center Capacity Calendar Hours Available Machines The work center number of machines should be at least as high as the number of machines per operation for this work center and for operations that use this work center QAD 32 User Guide QAD Manufacturing Fig 3 4 Standard Operation Maintenance 14 9 b See Lead Times on page 37 FAQAD Standard Operations Often routings share one or more operations that are essentially the same For example an automated packaging process may be the same regardless of the color of the products packaged To save work when entering new routing operations you can create template steps called standard operations When you enter a new routing operation automatically copy the standard data to the routing by referencing the standard operation code Then edit the standard information as needed Changes apply only to the new routing not to the standard operation you copied Note If you change a standard operation after referencing it on a routing the changes do not automatically apply to the existing routing Use Routing Update 14 13 7 to apply any changes you made to standard ope
22. Work Order Approval 23 10 these orders can be managed in the Work Orders module Releasing a sales order or service return material authorization RMA for a configured item to a work order in Sales Order Release to Work Order 8 13 Releasing an RMA receipt line to a work order with RMA Release to Work Order 11 7 1 5 Releasing a parent work order for an item with a routable component creates a related work order for the component Some work orders are created and managed in other modules These cannot be updated in Work Order Maintenance Work orders created by entering repetitive schedules are managed in the repetitive module Work orders created to handle customer service activities are managed with Call Activity Recording 11 1 1 13 in the Service Support Management module and Project Activity Recording 10 5 13 in the Project Realization Management module Customer services work orders are included on standard work order reports Work orders created by entering flow scheduled orders in Flow Schedule Maintenance 17 13 3 that do not include references to existing work orders are managed in the Flow Schedule module Work Orders 105 b See User Guide QAD Service Support Management for details b See User Guide QAD Lean Manufacturing QAD 106 User Guide QAD Manufacturing Fig 6 4 Work Order heit Maintenance 16 1 Work Order 1006 Go To Actions Type
23. as menu option 3 22 13 When activated additional frames display in some programs The discussion in this chapter assumes that WLT features are not active Setting Up Repetitive Setup activities for Repetitive are almost exactly the same as for Advanced Repetitive You need the same kind of base data such as items sites locations employees product structures and routings The programs used to set up production lines allocation percentages shifts and changeover times are identical in both modules Repetitive 229 Defining Control Program Settings Settings in Repetitive Control 18 24 differ from those in Advanced Repetitive Fig 9 1 zx Repetitive Control Repetitive Control Go To Actions 18 24 Next Picklist P L Prefix PL Consume Forward 0 Consume Back 0 Start of Week None Allow Zero Run Rate Next Picklist and P L Prefix Same as Repetitive Control 18 22 24 in Advanced Repetitive Consume Forward and Consume Back These fields in coordination For more with Start of Week determine how the system handles item pea see completions that exceed the quantity scheduled for a given day Completions on age 233 When Consume Back or Consume Forward is nonzero and you pag record more completions than scheduled the system consumes open quantities on past schedules then future schedules based on the number of calendar days specified in these fields Schedules with due dates before
24. conversion occurred This refers to for example any operation where a component is introduced and becomes part of the WIP material or where a rejected WIP material was reworked and assigned to a different lot serial The report shows the data recorded in these programs Purchase Order Receipts 5 13 1 Purchase Order Returns 5 13 7 Work Order Component Issue 16 10 Work Order Receipt 16 11 Work Order Operation Backflush 16 19 Labor Feedback by Work Order 16 20 1 Labor Feedback by Employee 16 20 2 Labor Feedback by Work Center 16 20 3 Repetitive Setup Transaction 18 13 Repetitive Labor Transaction 18 14 e Repetitive Rework Transaction 18 16 Repetitive Reject Transaction 18 17 Backflush Transaction 18 22 13 e Run Labor Transaction 18 22 14 Setup Labor Transaction 18 22 15 Rework Transaction 18 22 17 WIP Lot Non Convert Trans Report 3 22 13 16 Shows operation history data that references WIP lot and serial numbers but does not include records where material was converted WIP lot and serial numbers recorded during transactions in the following programs are reported e Repetitive Reject Transaction 18 17 e Reject Transaction 18 22 16 e Repetitive Rework Transaction 18 16 Rework Transaction 18 22 17 Repetitive Scrap Transaction 18 18 Scrap Transaction 18 22 18 WIP Adjust Transaction 18 22 21 Note Information recorded
25. picklists 122 receiving items 127 release date 115 releasing 120 routable 109 co product by product 84 routing 114 modifying 120 scheduling 115 scheduling operations 118 splitting 121 statuses 110 allocated 113 batch 112 closed 113 exploded 112 firm planned 112 planned 111 released 113 subcontract operations 126 tracing WIP 284 291 types cumulative 109 expense 108 final assembly 108 rework 107 scheduled 109 standard 106 user ID recorded 135 Index 403 Y yield 41 enabling operation based 359 example 42 including in repetitive schedules 159 material requirements planning MRP 364 368 MRP Control 359 work order 114 Yield field 41 FAQAD 404 User Guide QAD Manufacturing FAQAD
26. product structures 18 efficiency 151 employee 141 employee code when scrapping 222 Employee Create 36 1 7 1 141 employees efficiency 141 labor feedback 141 End Eff Days field 159 engineering change orders 23 engineering effectivity 23 exceptions BOM components 272 BOMs 272 routing 268 routing operation 270 expense work orders 108 expensed items 21 Exploded status work orders 240 exploded work orders 112 explosion advanced repetitive schedules 175 F FAS See final assembly FAS feature codes configured product 17 final assembly FAS work orders 108 finished items 224 firm category 241 firm planned work orders 112 Firm status work orders 240 first article inspections 317 fixed order quantity FOQ 363 floor stock 20 Index 393 expensed items vs 21 FOQ Fixed Order Quantity 363 Forecast Maintenance 338 Forecast Worksheet Maintenance 338 forecasting 319 342 adding methods 328 alpha factor 327 calculating forecasts 328 combining criteria templates 334 consumption 339 forward and backward 341 copying criteria templates 334 forecasts 332 results 334 creating detail records 329 creating forecasts 320 creating forecasts manually 330 criteria templates 322 329 detail records loading into summary forecast 337 loading methods 337 horizon 321 material requirements planning MRP 336 methods 325 best fit 326 classic decomposition 326 creating custom 327 double exponential smoothing 326 double movin
27. shown in Table 5 6 Co By product Order Quantity Orange Juice Co product 50 liters Pulp Co product 30 kg Seeds By product 10 kg The base process unit of measure UM is KG kilograms For the first co product orange juice the conversion factor between the base process and co product units of measure is 1 2 liters LT per 1 0 KG gt For more information on work order variances see Work Order Accounting Close on page 135 Fig 5 10 Sample Co By product Structure Table 5 6 Sample Co product and By product Order Quantities FAQAD 92 User Guide QAD Manufacturing Table 5 7 Sample Co product and By product Costs Table 5 8 Sample Co product and By product Yields FAQAD Co product and by product costs are shown in Table 5 7 Co By product Standard Cost Orange Juice 1 50 per LT Pulp 0 50 per KG Seeds 0 60 per KG For a given joint order set actual co product and by product yields are as shown in Table 5 8 Qty Qty Order ID Product Complete Rejected 1001 Orange Juice 55 liters 1 liter 1002 Pulp 25 kg 3kg 1003 Seeds 15 kg Okg Note Although a single example is used to illustrate all five quantity complete methods some methods may be more appropriate to particular process environments than others To display numeric values in the following examples these conventions are used Currency amounts are rounded to the nearest hundreth Non currency decimal value
28. under the same forecast ID as the detail record Modifying Forecast Results Forecast quantities may require modification to be more reflective of future market demand This is especially true when forecast results are based on historical data that included unprecedented sales for example sales due to a sales promotion or a natural disaster When you believe that future demand will not be similar to sales history you can adjust existing forecast detail records accordingly Note Modify forecast detail records as needed before copying forecast quantities to the summary forecasts used by MRP You can use Detail Forecast Maintenance 22 7 7 to modify forecast detail records produced by forecast calculations or loaded into the system using the CIM interface Forecasting Master Schedule Planning 331 Fig 12 5 eax Detail Forecast Detail Forecast Maintenance Go To Actions Maintenance 22 7 7 Forecast ID 2007 9 Method 00 Forecast Year 2007 Item Number 3 BB 49 UM EA Year Month Original Forecast Adjusted Forecast 2007 January 2000 2000 2007 February 2000 2000 2007 March 2000 2000 2007 April 2050 2050 2007 May 2200 2200 2007 June 2500 2500 2007 July 2700 2700 2007 August 3000 3000 2007 September 2700 2700 2007 October 2500 2500 2007 November 2050 2050 2007 December 2000 2000 Total 27 700 27 700 Select a forecast detail record to modify by specifying a forecast ID and forecast year To select a forecast de
29. 1 Forecasting Simulation Information Flow FAQAD 322 User Guide QAD Manufacturing FAQAD To produce a forecast for a given year you must specify a forecast ending year that is earlier than the forecast year To produce a 12 month rolling forecast beginning in the current month the ending year must be the same as the forecast year Note The system defines the first week of a new calendar year as the first Thursday in January in accordance with ISO standards Setting Up Forecasting Simulation Forecasting simulation programs analyze shipment history data in the customer product sales history cph_hist table For shipment history to post to cph_hist Integrate with SA must be Yes in Sales Order Control 7 1 24 Creating Criteria Templates Producing a forecast begins with defining a criteria template Criteria templates indicate which sales history to analyze and how the system should perform