Professional Documents
Culture Documents
Chapter 12
Chapter 12
Manufacturing
Material Production Control provides the necessary tools to manage the balance between demand and
resources in modern manufacturing environments. The module is designed to follow a data flow modeled on
the MRP principle. This principle starts with the entry of Master Planning data (e.g., from a sales forecast to
MPS and finally, to MRP to provide detailed replenishment proposals, culminating in shop floor control for
day-to-day production management).
MPC parameters are item specific. Production Work Centres and Operations are represented in MPC. Stock
plans can be developed by creating Forecast Demand. Costing models provide user-defined cost calculations
and transaction journals.
221
MANUFACTURING
Module Overview
The two diagrams show schematic views of demand and
resource data flow, together with the static data needed to
support the functionality contained within MPC.
222
MANUFACTURING
Getting Started
The main routines you use regularly for working with the MPC module are described in this section.
Add Item Data
To add item data, expand the MPC folder, expand the Basic MPC Data folder, and select Enter/Adjust Item.
Note: See Chapter 7 - Managing Stock for more information on the stock entry
screen or online help.
223
MANUFACTURING
224
MANUFACTURING
Enter a Configuration
code for items Configured
to Order.
10
11
12
7
8
10
11
12
Select the
LEADTIME/FORECAST option
on the MPC Data menu.
225
MANUFACTURING
13
14
13
To use a different
Leadtime for the MRP
Calculation, enter the
number of calendar days.
14
Note: The lead time can be calculated using a special Lead Time Calculation routine.
Create a Bill of Materials
To create a bill of materials, expand the MPC folder, expand the Basic MPC Dat folder, and select Enter/Adjust Bill of
Materials.
Enter/Select the
Operation Number from
the routing of the parent
to which this material is
consumed during
manufacture.
Enter/Select a
COMPONENT to be
used in the bill of
material.
5
6
7
Enter the QUANTITY required to manufacture the lot size of the parent.
226
MANUFACTURING
1
2
Enter the From Date from which the line will be effective.
1
4
2
3
1
2
3
4
3
4
227
MANUFACTURING
Enter a default
Queue Time and
Move Time in hours.
This is used when the
system schedules
work orders by
adding this time
before and after the
operation hours.
6
7
Enter the Calendar Collection to be used to calculate the Number of Working Hours. The average value in a working
day per year based on the specified calendar collection is calculated automatically.
228
MANUFACTURING
Press [Enter] or [PGDN] and enter any accounting defaults for the work centre.
10
10
Use Work Centre Calendars
A Work Centre calendar must exist before a work order can be scheduled.
To use work centre calendars, open MPC, MPC Basic Data, Enter/Adjust Work Centres, and Calculate Work Centre
Capacity.
1
2
Use Routings
To use routings, expand the MPC folder, expand the MPC Basic Data folder, and select Enter/Adjust Routing.
229
10
MANUFACTURING
4
5
6
7
Select the Cost Code to be used for the direct labor hourly
cost.
10
Accept or change the default OP DESCRIPTION taken from the Work Centre data.
Accept or change the default Set up hours taken from the Work Centre data.
The information in the Rate field is used to recalculate run time. Enter the number of items normally processed per hour,
and the run time is automatically calculated in the next field.
Planning
You can use Planning routines to generate forecasts for stock
Note: The same forecasts are used in SRP and MPC to
items and calculate requirements for their component materials. identify predicted demand.
You can also use it for production planning and to calculate
loading.
Enter a Forecast Demand
Forecasts can be entered for individual products or a forecast group. Typically, a forecast will be imported electronically by
expanding the MPC folder, expanding the Miscellaneous folder, and selecting Special Utilities. The following description shows
how to manually update a simple product forecast.
To enter a forecast demand, expand the MPC folder, expand the Master Planning folder, expand the Forecasting folder, expand
the Enter/Adjust Forecast folder, expand the Forecast folder, and select Stock Code.
1
3
5
If a Forecast already exists, the
window displays the existing
demand lines in the ROW field. The system takes you to the next line to be entered. Enter a demand quantity due on a day
or for a week, month, or year.
230
MANUFACTURING
Note: The columns showing Actual and Previous Year figures relate to the Sales
Invoiced quantities for that period.
2
3
To hold the total Gross Requirement for each item, set the Update Forecast in Stock File to Yes.
231
MANUFACTURING
Notice the Update Stock Planning function will act in the same way as the Move Forecast to Stock Plan option
described earlier.
1
Print the Rough-Cut Capacity
To print the rough-cut capacity, expand the MPC folder, expand the Master Planning folder, expand the Capacity Requirement
folder, expand the Capacity Req. from Forecast folder, and select Print Rough-Cut Capacity.
1
2
1
2
3
4
232
MANUFACTURING
Simulate changes to the No. of Resources, e.g. additional people Resources values.
To adjust MPS planned orders, use the tools found in the menu option Enter/Adjust MPS in the Master Planning Schedule
sub-folder in the Master Planning folder in MPC.
233
MANUFACTURING
1
2
3
4
6
5
7
8
9
10
12
Select the type of Planned Orders (i.e. proposals required from MRP). The default [PW] will produce both purchase and
work order proposals.
9
10
11
12
13
13
Enter the date up to which work order proposals are generated in the To Date Planned WO field.
Enter the date up to which purchase proposals are generated in the To Date Planned RP field.
To include All Purchase Items, enter [Yes] to only generate purchase proposals as a result of the MRP; or enter No.
Enter the range of Stock Codes to be included. Normally, an MRP is calculated for all Items in the stock file. You can set up
items to be excluded from MRP in the Item Master.
Enter Yes in the Create Load field to enable capacity planning reports to show proposed loading.
234
MANUFACTURING
6
2
4
5
235
MANUFACTURING
Use the Open item line tab to change the configuration of the Insert/Edit box of the Open item routine. If the Display
parameter is selected, the row is displayed.
Use the Line menu tab to change the commands menu configuration of the MPC BoM Configuration. If the Menu item
parameter is selected, the command is accessible in the context menu in the grid mode of the BoM line. Use the Button
checkbox to display the command in the main field of the BoM line.
Use the last tab to set parameters for Extra Descriptions. If the Display parameter is set, the text lines with brief
descriptions for open items and accessories are displayed.
Each tab contains buttons for moving the current field (Move up and Move down), storing current configuration (Store),
and restoring the original configuration (Restore default).
1
2
236
MANUFACTURING
Note: You can use the Graphic view mode to view the tree structure of the BoM. It
displays all items with names, stock codes, operation numbers, quantities, UOMs, and
stock descriptions. Parent items and child items are linked to make BoM more visual. You
can toggle the graphic view on for both the whole BoM and any sub-item. To toggle this
mode on, select any item and press the Graphic View button on in the Grid View
window. A tree will be displayed, with the selected item as a top.
Note: The list of available commands is configured in the Line menu tab of the MPC BoM
Configuration Setup program.
1
2
Create an accessory
list using the MPC
BoM Configuration
commands. Press the
Insert button to add a
subnode. Right-click
on the Node name
to display available
commands.
237
MANUFACTURING
Production Management
The Production Management section describes generating, inspecting, and changing work orders in MPC and how they affect
production capacity and materials.
Process Work Orders
To process work orders, expand the MPC folder, expand the Order Planning folder, and select Enter/Adjust Work Orders.
In the WO Number
field, select a letter A-Z
to use a pre-determined Note: Use [PgDn] in the Product Code field to select existing WOs sorted by different
criteria, or enter [C] in this field to copy a WO.
counter, or enter the
number manually.
4
5
6
7
A sub-menu window appears. Users can further change the selected WO. Select ADDITIONAL WO-DATA to enter additional WO
data.
238
MANUFACTURING
10
14
10
12
11
12
11
239
MANUFACTURING
13
14
13
15
15
Press [Esc] from the next sub-menu window. This takes the user
back to the starting point, ready to enter the next WO. To exit
the program, press [Esc] twice.
240
MANUFACTURING
Note: If the sales order includes items that have open lists, these should be
confirmed or adjusted.
To start the conversion, press
[PgDn] from the first field of a
row. The system asks for a Counter
A-Z to use for the WO numbering
and if a log list is required of the
conversion data.
Note: To exit the program before conversion, enter [Esc] to exit each window until
another window opens reminding you there are still records in the batch queue.
Press Yes after the system prompts to quit; in the following window choose to
Select More customers, and press [Esc] to the go back to the menu.
3
4
241
MANUFACTURING
Note: Be careful not to select too many proposals at one time. To exclude a
proposal, the quantity must be set to zero.
1
2
3
4
242
MANUFACTURING
1
2
3
4
Note: The Schedule column indicates the sequence of operations to be worked on.
The number 999 indicates the operation has not been scheduled. To change the
sequence, simply go to the required operation, and type the number in the schedule
to where the operation should be moved.
243
MANUFACTURING
Material Control
Routines in this section provide calculating net requirements from forecasts, planned orders, and current orders and delivering
information about the availability of material/component needs for orders.
Review Proposed Actions
As a result of each MRP calculation, the system lists proposed actions. These actions may include adjusting existing orders or
creating new ones.
To review proposed actions, expand the MPC folder, expand the Material Requirement Planning folder, expand the Reports
folder, and select Print Action List.
244
MANUFACTURING
7
8
1
2
3
4
5
6
7
10
8
9
10
Note: One Purchase Order per supplier will be generated. Be careful to restrict the
number of lines; the only way to not convert a line is to enter zero as the quantity
on that line.
Check Component Availability
There are many standard reports that estimate the availability of material/components needed for work orders and/or sales orders
To check component availability, expand the MPC folder, expand the Analyze Material folder, and select Mat. Avail. Test,
Simulation.
1
2
3
2
3
245
MANUFACTURING
7
8
9
4
5
6
7
8
9
Enter the Shortage, Date after which shortages are not shown.
Enter the Horizon, Date to which the stock planning data for each shortage will be displayed.
Enter the Type of Display to indicate how information should be formatted on the screen. Enter [W] for week. To see all
expected receipts and issues as transactions, leave this field as [T].
The screen displays the header information (i.e., item and quantity of the parent); each subsequent window displays a mini
planning report for items not available and for those that would prevent manufacture.
View a Demand Report
To view a demand report, expand the MPC folder, expand the Analyze Material folder, expand the Other Demands Report
folder, and select Planning List per Transaction.
This planning report displays all expected stock movements.
Consume Materials and/or Components to a Production Order
Depending on parameter settings, the system provides a number of ways to consume material/components to a production order.
A company with repetitive production may choose to automatically consume based on the finished product manufactured
(backflush). Alternatively, an engineering company may choose to manually update consumption at the time of picking for a
production order.
246
MANUFACTURING
To consume materials and/or components to a production order, expand the MPC folder, expand the Reporting folder, and select
Material issues, by WO.
1
2
4
5
3
3
To accept the system expected Note: Depending on the component master data, the system displays a screen to
issue quantity for all remaining specify the Batch from which the component is consumed.
lines, simply enter [a] in the
ROW field; to change a line
detail, enter the line number.
4
5
247
MANUFACTURING
1
2
Note: Users can allocate more than one batch to reserve, up to the
required quantity.
248
MANUFACTURING
1
2
3
4
5
6
Note: To report work orders where the allocated quantity is incorrect, repeat the
above steps after selecting the sub-menu option Check invalid Allocated QTY
on Batches.
Note: To lock all expired batches so they cannot be used, expand the MPC folder,
expand the Batch Allocations folder, and select Lock Expired Batches.
Production Reporting
Reporting is used to provide manual entry into the system of the completed work and the materials issued. You can report waste,
scrap, down time, receipts to other warehouses, and so on.
Report Production Operations Data
To expand the MPC folder, expand the Reporting folder, and select Operation Report.
249
MANUFACTURING
2
5
Note: For batch and quality controlled items, additional screens will open to enter the
required information.
Note: You only see work orders ready for Closing i.e. status 7. Be careful with the
date range. (It does not link to a chosen WO.) Closed work orders have status 8.
250
MANUFACTURING
1
2
251
MANUFACTURING
1
2
3
Enter the hourly rate for Direct Labour, and enter a rate for Direct Labour, Setup cost. Leave the Indirect Labour Cost
blank.
1
2
252
MANUFACTURING
Enter the
multiplication Factor.
Press [PgDn] to exit
the program.
1
2
2
3
4
253
MANUFACTURING
3
4
5
1
2
3
4
254
MANUFACTURING
Notice the system shows the cost model and a sub menu
to allow changes to the Bill of Materials, Routings, Cost
Factors, or the cost model. After making the required
changes, select the option Cost Calculation to see the
resulting Product Cost.
255
MANUFACTURING
To use actual costing, expand the MPC folder, expand the Actual Cost/Statistics/WIP folder, expand the Actual Cost folder, and
select Enter/Adjust Actual Cost.
256
MANUFACTURING
Enter the Number for the selection range e.g., [2] - the
Work Order Number range. Enter a Work Order to view
the WIP value.
In the next window, select the Sorting Order for the report e.g. 2
sorts by Item Code.
257
MANUFACTURING
In the pop-up screen, enter Yes in the View Transactions field to view the transactions on screen, or to go directly to the
posting, accept No.
2
3
Note: The accounts are pre-defined in the MPC Auto Accounting Schedule;
typically, these will be a WIP Account, Stock Accrual, WIP Material, and WIP
Labor Account. Only cost transactions defined in the Costing Models are seen
in the WIP journal. Work Orders must be finished before you can see any
Variance transactions.
Management Information
This section describes various enquiry and reporting routines.
Enquire an Item
The Item Enquiry provides information about item statistics,
static data (item set-up), plus the current stock and planning
information. Information screens are activated by entering the
letter code shown for the sub-menu option.
To enquire an item, expand the MPC folder, expand the
Enquiries folder, and select Item, MPC.
In the window that opens, type in a stock code, and press
[Enter].
258
MANUFACTURING
4
5
From the next pop-up menu, select option 1 Details for the Line.
The enquiry screen provides reservation and issuance data. Press [Esc] four times to return back to the menu.
1
2
3
In the window that opens, select a Work Centre for the enquiry, or browse using [F4].
To view available capacity, select the sub-menu option 4 Available Capacity/Week. Press [Enter] to scroll forward.
The screen displays the capacity and the available capacity for the next six months. Press [Esc] four times to return back to
the main menu.
259
MANUFACTURING
1
2
In the window that opens, enter the number related to the selection range e.g., [1] for the Work Order Number range.
In the next window, enter [0] to accept the default document code. The last step before printing the report is to select
the output format.
Press [PgDn] for further selection criteria, or press [Enter] to go to the Sorting Order window; enter a number to select the
sorting order.
1
2
3
The printout shows all of the scheduled operations for each Work Centre. For each operation, the report shows both planned
hours and reported hours for set-up and runtime.
Run MPC Statistics
To run MPC statistics, expand the MPC folder, expand the Actual Costs/Statistics/WIP folder, expand the MPC Statistics folder,
and select MPC Statistics Print-Out.
In the selection window that opens select the Data Range for the report, e.g., enter [1] and press [F4] to select a range of
Work Centres.
Note: There are 47 fields available to select as content in this report. Enter a
number that corresponds to the data e.g., enter [2] to include an item
description. Enter [PgDn] to see the next window of the data fields.
260
MANUFACTURING
1
2
3
In the selection window that opens, make the data selection range for the costing report e.g., select a Stock Code.
Complete the fields, as required, accepting default values where applicable.
In the All Levels prompt screen, enter Yes to see costing data for Material/Components at all levels in the Bill of Material for
the parent costing.
The resulting printout shows each component from the bill of material at all levels, first listing the purchased items and then the
manufactured items.
261
262