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WS: 30: How To Set Up and Overview of Repetitive Manufacturing [ID


828665.1]

Modified 18-JUN-2009 Type BULLETIN Status PUBLISHED

In this Document
Purpose
Scope and Application
WS: 30: How To Set Up and Overview of Repetitive Manufacturing
Overview
Set up
Shop Floor Calendar/Work Center/Resource Units Matrix
Working with Rate Schedules
Line Schedule Review
Line Scheduling Workbench
Line Sequencing Workbench
Rate Completions Workbench
Production Status
Production History

Applies to:

JD Edwards World Product Data Management - Version: A8.1 cume 2 - Release: A8.1

Information in this document applies to any platform.

Purpose

The purpose of this document is to provide the user with an overview of the set-up and outline the basic
functionality of JD Edwards World Repetitive Manufacturing as it applies to releases post A7.3.

For A7.3 refer to the Rate Schedule Overview document ID 627256.1.

Scope and Application

Users responsible for manufacturing system setup for Repetitive Schedules benefit from this document.

WS: 30: How To Set Up and Overview of Repetitive Manufacturing

Overview

A repetitive manufacturing environment exists where demand for an item is steady and consistent enough such
that a manufacturer may want to establish a rate schedule to produce a specified quantity of items over a given
time period. This will eliminate the need to create and maintain multiple work orders. Typically these items are low
cost, short lead-time items with a steady demand for which a manufacturer does not mind carrying excess
inventory.

Set up

Item Master/Item Branch (G4111)

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Define a stocking type M, manufactured item. Select F10 to reach the Plant Manufacturing Data to
populate the following:

Issue and Receipt: A code that indicates whether or not an item is received at the time of inventory issue.
Also known as Pay on Consumption. Valid values are:

0 No action taken
1 The system receives the item when inventory issue occurs
2 The system uses Movement and Disposition when inventory issues occur

Replenishment Lead Time: The amount of time in hours, before a consuming location has a replacement
Kanban available from its supplying location.

Order Policy Code: the code that designates the rules for re-order. Rate Schedules must be coded as 5.

Value Order Policy: The desired inventory level when you select order policy code 5 (rate scheduled item).
MPS/MRP/DRP generation issues an "increase rate to" or a "decrease rate to" message based on this
quantity.

Manufacturing Constants (G3041)

Status For Changes: The status beyond which rates schedules cannot be changed in the Line Scheduling
and Line Sequencing Workbench Programs.

Work Hours per Day*: The number of hours that the manufacturing plant operates per day.

Hours per Shift*: For repetitive manufacturing, identify the number of work hours per shift for the specified
branch. The Resource Generation program uses the corresponding shift hours to calculate the available
resource units for each shift, and the total for the day.

Work Center Master (G3011)

Work Center Type*: Defines the type of work center. Valid values are:

0 Stand alone work center


1 Production line in a repetitive environment

For repetitive manufacturing, the system verifies the value is not valid as a work center for an operation
from the routing.

Location Issue: The location from which inventory is moved.


Hours per Shift*: The number of hours that the Work Center operates per day.
Standard Capacity*: The capacity stated in units per hour that the line operates at.
Capacity U. O. M. *: The unit of measure to state the capacity of a production line.
Minimum Capacity*: The lower limit of the production line stated in units per hour.
Maximum Capacity*: The maximum limit of the production line stated in units per hour.

Set up the Shop Floor Calendar By Shift (G3041) *

Set up Resource Units by Shift (G3141)

Set up Line/Item Relationships (G3141)

A default Line/Item Relationship MUST be set up for each rate schedule item. Default information from the Line
Item Relationships is used in the following areas:

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 Determines the existing load by and item on a production line. Example: If 100 of an item are scheduled on
a given day, and it takes 2 injections to make the item, then the load is 200 injections on that line for that
day.
 The default is used for MRP when generating Create Rate messages.The MRP program uses the Period
for placing the correct dates in the messages. The message program uses the Line/Cell and Shift for
creating the rate. Note that there can be only one default for an item regardless of the number of lines that
the item can be produced on.

Routing

Define the Line/Cell in the Routing (LINE) for your Rate Scheduled item.

 Resource Units – This can be used if it is desired to have a different unit of measure for a work center,
other than hours on an individual routing step. The UOM defaults from the WC Master. In order to use this
feature, Capacity STD, UOM, Min and Max must be entered on the WC Master. It is not necessary to
define the work center as a production line.
 Consuming Location – In addition to “Backflushing” by work center location, this provides the ability to
back-flush by each routing step. The logic will check the routing step before the work center.

* Note: All of these values will factor into determining Resource Units.

Shop Floor Calendar/Work Center/Resource Units Matrix

Examples of resulting resource units for typical values that might be entered in the Shop Calendar, Work Center
Master, and Manufacturing Constants:

Working with Rate Schedules

1. Rate Schedules are recorded in the Work Order File F4801, and the Rate Schedule Quantity Detail File
F31091.
2. Rates have parts lists and routings, just like Work Orders. They can be attached either interactively, or by
using the Process Work Orders batch program P31410. This is controlled by the PARTS LIST/ROUTING
CREATION processing option on P3109.
3. Rate ‘Period’ is defined as Day, Weekly, or Monthly. Rate Schedules will not use the level lead-time from
the F4102 Table. A rate that is defined as ‘daily’ will start and end on the same day.
• If a rate is defined as weekly, the ‘from’ and ‘through’ dates must be greater than or equal to the Sunday,
and less than or equal to the Saturday of the week.
• If a rate is defined as monthly, the ‘from’ and ‘through’ dates must be greater than or equal to the first of
the month and less than or equal to the last day of the month.
• The concept of having a weekly or monthly rate running across calendar weeks and/or months is not
valid. Rate must be for the period defined. Any left over amount from a rate does not carry over to the next
period.
4. The Line/Item Relationships determine the defaults for creation of rates from MRP messages.
5. Shift can be entered for a rate. If it is left blank, it is defaulted to a 1.

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Line Schedule Review

The Line Schedule Review shows the load against a given line by item or for all items. Capacity and Capacity
UOM is from the Resource Units for the specified line.

Line Scheduling Workbench

The Line Scheduling Workbench is used to view Rates, Planned Rates, Work Orders and Planned Work Orders
on the days that they are scheduled to be produced. The main functions on the Workbench are:

 Changing and moving quantities to the same line.


 Splitting quantities to one or more lines.
 Change the status of a Rate/Work Order.

Line Sequencing Workbench

The purpose of the Line Sequencing Workbench is to sequence the rates and work orders in the order that they
are to be produced. Different type or styles of products may need to be grouped together to reduce setup time.
There are two methods to sequence the rates:

 By sequence
 By category code (from the Rate Schedule)

Rate Completions Workbench

Completion of Rate Schedules is done through the Rate Completions Workbench. Note the processing options,
Super back-flush is called, and there is no ‘blind’ mode.

Production Status

This inquiry provides a complete status on Work Orders and Rates, for a specified line, item, date range, and
status.

Production History

This inquiry provides the detail for all of the transactions against a rate schedule.

Related

Products

 JD Edwards World > Supply Chain Management > Manufacturing > JD Edwards World Product Data
Management

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