- Planning bills of material do not change released work
orders or production routings until specifically changed by engineering.
- Entries are automated from labor reporting and material
issues. Purchased materials or outside services may be distributed directly from A/P.
- Costs evaluated timely. Up-to-date costs are tracked by work
order with on-line inquiry capability for job-to-date data. Closing summaries are timely,
available for immediate review and invoicing.
- Clerical effort reduced. Costs from A/P, labor and material
reporting and miscellaneous charges need only one input of data. Burden as percentage or
cost of labor or material is automatically calculated.
- Material shortages reduced. MRP prints shortage lists for
any future date based upon manufacturing requirements and the sales/service forecast.
- Pegging allows examination of current and/or future orders
by a vendor or production shortage.
- Take a planned approach to predicting short- and long-term
bottlenecks.
- Reduce inventory and manufacturing costs. Through the use of
MRP reports, material is not purchased and/or delivered until it is needed.
"JIT" inventory philosophy may be applied.
- Increase productivity. Planning helps bring the right
material, the right equipment and the right manpower to the right place at the right time.
Work Order Control
| Feature |
Function |
| Work Order Entry |
Create a work order using
customer number, sales order number or system generated sequence. Enter part number,
quantity, required date and routing. The routing can be manually entered, retrieved from
the routing file as a single or multi level routing, or created from the bill of material.
The work order can use subassemblies or build from component/material level or a
combination of both. Using standard run time per unit, setup time, quantities, required
date and a manufacturing calendar, a suggested release date is calculated (backward
scheduled at creation). Once accepted, each step is forward scheduled with a calculated
release date supplied. Component/material and subassembly usage will update inventory as
'committed' while the part number and subassemblies being produced updates as 'on-order'. |
| Work Order Progress |
Enter partial of full work order
completion and quantity. On-hand and On-order values and new average cost for the part
produced. Closed work orders will update work order history for analysis retention. |
| Work Order Maintenance |
Work orders may be modified for
various reasons including step reschedule, work center change, number of available shifts,
work hours available, labor or material burden factors, adding, deleting and changing
steps. Work orders may be reprinted after modification. |
| Work Order Reschedule |
Reschedule an entire or selected
steps within an order. Steps following the one modified will be updated automatically and
rescheduled with new dates unless a step has already started. Any steps not desired to be
rescheduled may be overridden. Work orders may be reprinted after modification. |
| Work Center Maintenance |
Create and maintain data
pertaining to work centers within the production environment such as descriptions, number
of shifts, total available hours, number of men or work calls, efficiency and utilization
percents, burden rates and normal queue time. |
| Work Order Quote |
Create a work order cost estimate
or price quote based on quantity and material, labor and burden markup. |
| Work Order History |
Display or print in summary or
detail data pertaining to closed work orders. Access by work order, range of dates or
inventory number. Data is available for creating analysis reports. |
| Production Calendar Maintenance |
Enter and maintain holidays and
plant closings for use by work order scheduling. |
Labor Reporting
| Feature |
Function |
| Labor Entry and Edit |
Enter and edit labor time by
employee for each work order and operation. Labor may be entered via bar-coded labor
tickets and preprinted employee cards. Labor rate is taken from the employee master file,
work center standard or applied at entry time. Each entry allows run time and setup time
to be applied separately as in/out clock time or elapsed time. Labor rates may be
designated as regular, overtime or premium time and may directly feed payroll
calculations. The labor entry edit list prints in employee sequence all entries made
during entry. Changes can be made in labor entry and reprinted as needed. Once accepted,
the labor entry register is printed for final verification and audit. Acceptance updates
reported work orders, the labor payroll transfer file, variance reporting file and work in
process costing files. |
| Attendance Card Entry |
Total hours entered by employee
balances against labor entry times and prints variances. |
| Labor Efficiency Reports |
The labor variance by employee
report list standard hours versus actual hours, the efficiency percent, the original hours
estimated, the actual hours used and the variance for each work order operation based on
number of units completed to date. The labor variance by work center reflects each work
order operation in process or completed since last report run. |
| Dispatch Lists |
Printed by work center, the
dispatch list reflects all work expected at a work center by release date and work order
operation. A user-supplied cutoff date limits the time fence which could potentially be
one shift, one day, one week or one month. |
Material
Reporting
| Feature |
Function |
| Material Reporting |
Enter and edit material issued to
a work order. Material may be entered via bar-coded material pick tickets or preprinted
material cards. Substitute parts may be entered as an override to expected material.
Quantities larger or smaller than expected may be entered due to scrap, overrun or
underrun. A backflushing option will automatically report all material issued based on
material requirements found on work order; exceptions should be reported before
backflushing. The material issues register prints an audit trail of materials issued via
standard and backflush reporting. Once accepted, work orders, work in process and raw
material general ledger and inventory master files are updated. |
| Material Shortage Report |
A report in component/material
sequence of any component/material inventory level falling negative within a user supplied
time fence. The report lists all open orders (purchase, sales, work an etc.) for a
component/material, easing analysis. |
Routings
| Feature |
Function |
| Material Entry and Edit |
Enter and edit manufactured
parts, including labor and material operations. Data includes work center, operation code,
component/material and quantity if applicable, setup hours per unit, machine number, tool
number and move time. Once entered, the routing becomes standard for the labor and
material required to make the manufactured part. |
| Automatic Routing Creation |
Creates a routing from a single-
or multi-level explosion of the bill of material. |
| Same-As-Except-For |
Create and edit a routing by
duplicating an existing routing. Change, add and delete existing operations. Also may be
used as an estimating tool in conjunction with work order estimating. |
Net
Material Requirements
| Feature |
Function |
| Net Posting |
Posts net requirements by
comparing available quantity (on-hand and on-order - committed - required) to reorder
point. Parts below reorder point are exploded one level with subassembly or
component/material requirement increased according to amount required. The process
continues through the component/material level. The reorder calculation uses discrete,
min/max or EOQ depending upon master inventory file indicator. |
| Net Requirements Reorder Report |
Report by work center and/or
vendor of all subassemblies and/or component/material which need to be reordered as
determined by Net Posting. Report lists recommended reorder quantity, on-hand quantity,
on-order, quantity committed and quantity required. |
Single
Level Bills of Material
| Feature |
Function |
| Product Structure Maintenance |
The bill of material is built
using a parent-to-component/material list relationship. Once a subassembly is entered, an
entry of the subassembly part number will automatically link all component/materials to
the new parent. Relationships may be added, changed or deleted easily. Entries are
validated to assure parts and components/materials exist and that a structure is not
linked to itself. All component/material where used is maintained automatically. |
| Single Level Parts |
Display or print the next lower
level subassembly or component/material for a parent part or range of parts. This function
provides an assembly or component/material acquisition listing, component/material and
subassembly requirements planning explosion, engineering change review, and assembly cost
listing for quantity required. |
| Single Level Where Used |
Display or print the total usage
of this assembly or component/material at the next higher level. This function can be used
to quickly determine the effect of assembly or component/material allocation or
engineering changes. |
Multi
Level Bills of Material
| Feature |
Function |
| Indented Parts List |
Display or print the entire (up
to 99 levels) bill of material structure (explosion) for a parent part or range of parts.
This function can be used for production planning of assemblies, component/material
ordering, determining product cost breakdowns and for service parts cataloging. |
| Indented Where Used |
Display or print the bill of
material higher level where used (implosion) for an assembly or component/material or a
range. This function can be used for quickly identifying where assemblies and/or
components/materials may affect production or be affected by an engineering change or cost
increase/decrease. |
| Indented Quantity Inquiry |
Display or print an indented
parts list with the addition of stock status, lead time and reorder point information
listed. This function can be used for identifying assembly and component/material
availability, normal lead times and initiating timely purchase and/or work orders. |
| Indented Cost Buildup |
Display or print an indented
parts list with the addition of actual and standard material cost, actual and standard
labor cost, actual and standard burden cost and total actual and standard costs. This
function can be used to review cost variances. |
| Cost Buildup |
This function accumulates the
last actual cost to produce one unit of an assembly. Cost buildup includes actual
material, labor and burden cost from last purchase of a component/material or production
run of a subassembly. The cost buildup register will print the old and new average cost
for the assembly. Once accepted, the average cost field in the inventory master record
will be updated to reflect new average cost. |
| Summarized Parts List |
Display or print the total usage
(explosion) of each component/material within a selected assembly or subassembly or a
range. This function is used to determine product costing, master production schedule
planning and gross material requirements. |
| Summarized Where Used |
Display or print the total usage
(implosion) of this subassembly or component/material at each higher level. This function
can be used to determine higher level usage of subassemblies or component/materials
affected by an engineering change, shortage or cost change. |
| Delete/Replace Entire BOM
Structure |
Instead of deleting or replacing
each component/material used, this function allows the entire bill of material to be
deleted or replaced with a single entry. |
| Delete/Replace Component/Material
Where Used |
This function allows for a single
entry to replace or delete a component/material in every bill of material where it is
used. |
| Same-As-Except-For Entry |
This function allows for the
creation of a new part number (user or system provided) and a new bill of material based
on a existing product and its structure. Components and quantities may be added, changed
or deleted from the new bill of material as needed to reflect differences from existing
product. |
Work Order
Costing
| Feature |
Function |
| Labor Burden Calculation Register |
Reports the burden calculated for
each labor entry by employee within work order. Burden may be an hourly rate or percentage
of labor dollars. Burden values may be added as a cost to work orders. |
| Miscellaneous Charges Entry |
Enter and maintain charges to a
work order. Types of charges include labor, material, equipment, services, surcharges or
miscellaneous. Typically records outside services desired to be applied before vendor
invoice available. An audit trail by work order of added charges is provided. |
| Work Order & WIP Costing
Register |
On-demand report of costs
accumulated from labor reporting, material issues, accounts payable and miscellaneous
charges. Prints G/L distribution of costs report for edit before update. |
| Work Order Cost Inquiry |
The total current cost of a work
order is broken down into labor, material and other operations in this on demand inquiry. |
| Work Order Cost Report |
Print the status of all or
selected work orders with regard to costs broken down into labor, material and other. |
| Work Order Progress Cost Register |
Register of costs by work order
for which finished goods (partial or complete) have been reported. A report print
distribution of WIP to finished goods reported to general ledger. |
| Work Order Cost G/L Summary |
A summary by general ledger
account within work order of amounts applied. |
Work Order
Budgeting
| Feature |
Function |
| Work Order Budget Entry |
Enter work order budget values by
operation, cost type or by total work order. A work order budget report is printed as an
audit trail. |
| Work Order Variance Report |
A report of all or selected work
orders showing cumulative costs by cost code, by operation, by work order and the budget
variance to date. |
Master
Scheduling
| Feature |
Function |
| Master Schedule Entry |
Enter expected sales, service or
demand for finished goods, subassemblies, engineering requirements or service parts in
addition to entering firm planned work orders. Entries are validated against bills of
material and routings, entries consist of part number, quantity and date required.
Existing firm planned orders may be changed or deleted. |
| Firm and Released Order Print |
This report shows all orders by
part number which will be used by MRP and capacity planning in projecting manpower,
equipment and material needs. |
| Convert Planned Orders to Firm
Orders |
A simple entry converts planed
orders from MRP to firm planned orders for Master Scheduling. |
Material
Requirements Planning
| Feature |
Function |
| MRP Regeneration |
All product demand entered into
the Master Schedule is exploded in time phased sequence in lower level requirements based
on the planning bill of materials. Work orders, purchase orders and sales orders are
automatically included. Each requirement is netted against the beginning inventory
balance. If available inventory falls negative, a planned work order is generated. In
turn, the planned work order is netted until component/material requirements create
planned purchase orders. MRP regeneration will allow the planner to set up time fences and
will recommend expediting firm orders when necessary. Up to seven lot sizes policies may
be utilized. |
| MRP Inquiry |
Displays all MRP demand and
fulfillment in date sequence by part number. Used to quickly check any unusual or
questionable planned or firm orders or to determine reschedule potential. |
| MRP Report |
A complete listing of all
transactions used in MRP generation. This report is printed in part number sequence and is
normally printed only when requirements appear suspect. |
| MRP Planned Order Report |
Actually two reports which list
all of the planed work orders and planned purchase orders created MRP generation. These
planned orders can be used in the master scheduling to create firm planned orders. |
| MRP Action Report |
The exception report indicates
potential scheduling problems. The information is in detail and will allow production
personnel to determine if a firm planned order should be rescheduled to prevent a material
shortage or missing a required customer delivery date. |
| Pegging Requirements |
This on-line inquiry displays
what part number, at a higher level in the bill of materials, caused specific requirements
in the MRP generation. Utilized effectively to track customer and/or work orders which may
be effected by material and/or manpower shortages and take appropriate measures. |
| Normalize Lead Times |
Report and update that summarizes
the last lead time data from routings and updates the item master records. This allows for
faster scheduling of work orders in MRP programs. |
| MRP Net Change |
Net change is driven from a
transaction file which accumulates all planned or actual inventory activity. The net
change task may be run on-line or batch mode to 'net' the effect of the requirements and
issue 'action' items to the planned order and action reports. The netting may be set up as
single or multi explosion of demand changes. An audit trail of all planned or actual
inventory transactions that pass through MRP net change is provided. |
Capacity
Planning
| Feature |
Function |
| Capacity Loading |
The planned work orders from MRP
generation, the firm planned orders from master scheduling and/or released work orders are
combined by date and work center into the man/machine hours needed for production. Setup
time, run time and move time are extended by operation in date sequence. A shop calendar
is utilized for scheduling non-work days such as holidays or planned shut downs. Time
fences may be set by the scheduler. |
| Capacity Report (Summary) |
A report generated by Capacity
Loading which graphically depicts the load by day at each work center. A cumulative load
factor is also calculated and shown. This percentage factor predicts the need for an
additional shift/equipment or subcontracting. This same information is available by work
center as an on-line inquiry. |
| Capacity Inquiry (Detail) |
This inquiry will allow
production schedulers to find the specific work orders which have caused overloads. It
also will indicate any work already started or completed for rescheduling purposes. |
| Work Order Reschedule |
Rescheduling allows for the
changes to any released work order. Each operation an work center will be checked and take
into account any changed manpower, machine hours or routing. Lead times will be
recalculated and each operation will get a new scheduled start date. |
| Work Center File Maintenance |
Enter and maintain work center
information. An edit list is provided. |
Rough Cut
Planning
| Feature |
Function |
| Rough Cut Load |
This function uses the Master
Schedule (firm planned orders), MRP (Planned Orders), Released work orders and released
purchase orders to purchasing costs, labor costs and labor hours for review. Purchase
order cost may be selected from actual cost, average cost, standard cost or last actual
cost. The labor rate may be entered or retrieved from the work center file. Up to five
reporting periods an the number of periods per period may be defined (normally monthly or
quarterly). A Rough Cut P/O Cost Report spreads expected purchasing costs into the
predefined periods by vendor. A Rough Cut Capacity Report reviews capacity per period and
expected load by work center. Any load exceeding capacity is flagged. A Rough Cut Labor
Cost Report prints the expected labor costs by predefined period within work center. |
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