To effectively use Manufacturing, you must set up the manufacturing system to respond to your parameters and methods of operation. There are many choices and options so that processes and procedures can be defined based on what is most efficient and effective for the way in which you run your business.
The following windows are the basis of manufacturing setup:
Manufacturing Setup window
Production Schedule Setup window
As items or part numbers are created, set up decisions and settings must be established so that the items are planned, procured, and managed in inventory based on your specifications and operations model. (see Creating an Item Card)
You use the Manufacturing Setup window to specify how you want the program to manage your manufacturing operations.
The Manufacturing Setup contains data for work shifts and the number series to be used for work centers, routings, production orders, and so on. You must also specify other options such as how you want to post work in progress.
System Preconditions
No. Series are set up
Production Forecasts are set up
Locations are set up
Set up the program to manage manufacturing, including number series and default settings.
In the Normal Starting Time field, you enter the normal starting time of the workday. When refreshing a production order, the program looks to this field to get the starting time to do forward scheduling.
If you do not use capacity requirements planning, the BOM explosion in the planning worksheet is calculated by the lead time only.
In the Normal Ending Time field, you enter the normal ending time of a workday. When refreshing a production order, the program looks to this field to get the ending time to do back scheduling.
If you do not use capacity requirements planning, the BOM explosion in the planning worksheet is controlled by the lead time only.
In the Preset Output Quantity field you define what the system should show in the Output Quantity field of a production journal when it is first opened. The selection in this field does not affect the Output Journal. You can select between the following options:
Expected Quantity: presets the Output Quantity field to the same as the production order quantity, for all operations in a production journal.
Zero on All Operations: presets the Output Quantity field to zero on all operations in a production journal.
Zero on Last Operation: presets the Output Quantity field to zero on the last operation of a production journal and the Expected Quantity from the production order on the other lines.
Place a check mark in the Planning Warning field if you want the program to warn you when sales order lines meet certain conditions.
A warning may occur if planned sales cannot be met. For instance, a warning will be issued if a deadline which is impossible to meet is confirmed to the customer, or if a quantity which is impossible to manufacture in time is confirmed to deliver.
If changes are made to a sales order line that is tracked to a production order, a warning may occur so you can review and make any necessary changes to the production order.
Place a check mark in the Doc. No. Is Prod. Order No. field to instruct the program to use the released production order number for all ledger entries posted for the production order.
Place a check mark in the Dynamic Low-Level Code field if you want the program to automatically set the dynamic low-level code when a production BOM is certified.
If production BOM certification is time consuming, you can run the Calculate Low-Level Code batch job to globally calculate low-level code for all BOMs. This batch job must be run before the first Planning Worksheet is calculated.
Low-level codes must be calculated before you run the Calculate Plan batch job.
Place a check mark in the Cost Including Setup check box if you want the program to include the setup costs in the routing during cost calculations.
On the Numbering Tab, you select the code for the number series that you want the program to use when assigning numbers to the following manufacturing-related areas:
Simulated Production Orders
Planned Production Orders
Firm Planned Production Orders
Released Production Orders
Work Centers
Machine Centers
Production BOMs
Routings
In each field, click the AssistButton to see the number series in the No. Series window.
If you want to use more than one number series, you can set up a relationship between the relevant series in the No. Series Relationship window. This will allow you to use one code to represent two or more number series.
The fields on the Planning tab affect the information in the planning worksheet.
In the Current Production Forecast field, select the name of the relevant production forecast that the program will use to calculate a plan. This is a default setting that can be changed when you calculate the planning worksheet.
Place a check mark in the Use Forecast on Locations field to indicate whether you want the program to filter according to location when it calculates a plan. The program then nets actual demand against forecast demand for the specified location only.
If you leave the field blank, the program regards the production forecast as valid for all locations.
In the Default Safety Lead Time field, enter a date formula that the program will use as the default safety lead time if you have not filled in the Safety Lead Time field on the Item Card or the Stockkeeping Unit Card.
If you want the program to automatically calculate an MPS/MRP plan in one step, place a check mark in the Combined MPS/MRP Calculation field.
When you open the Calculate Plan - Plan. Wksh. batch job from the Planning Worksheet window, both the MPS and MRP fields will already be checked. You can remove one of the check marks if necessary.
If you leave the field blank, you can select either MPS or MRP on the Calculate Plan - Plan. Wksh. request form window. However, you cannot select both.
In the Components at Location field, select the inventory location from where the production order components are to be taken if you have not specified a location on a Stockkeeping Unit Card.
This field, together with the Locations Mandatory field, is very important in governing how the planning system handles demand lines with or without location codes.
Concerning production demand, the program will use the same location for components as the one stated on the production order. However, by filling in this field, you can redirect the components to another location. You can also fill in the Components at Location field on the Stockkeeping Unit Card. If you often need to plan for demand at locations, it is strongly advised to use the stockkeeping units feature.
In the Dampener (Time) field, enter a period of time during which you do not want the program to propose an action to reschedule the due date on an existing order outward in time.
The program then proposes such an action only after the period of time expires that you enter in the field.
You use a dampener in order to limit insignificant action messages when the program calculates a plan.
In the Dampener (% of Lot Size) field, enter a minimum quantity below which you do not want the program to propose an action to decrease the quantity on an existing order. The quantity entered in this field is a percentage of the quantity entered in the Lot Size field on the Item Card.
The program proposes such an action only when the quantity exceeds the amount that you enter in the field.
No action is proposed if the quantity is equal to the amount that you enter in the field.
You use the Production Schedule Setup window to set up the calendar period to be shown in the Production Schedule window, as well as define how progress is displayed.
Enter a starting date and ending date to define the total horizon of the window's time line, and set up how to show progress in the interaction pane.
In the Starting Date field, enter a date formula that defines the first day shown in the production schedule relative to the work date.
The default value is -1D, which means that the first day shown is the day before the work date.
In the Ending Date field, enter a date formula that defines the last day shown in the production schedule relative to the work date.
The default value is 2W, which means that the last day shown is two weeks after the work date.
The Progress Calculation field defines how the system should show progress on operations or orders in the production schedule. There are two Progress Calculation options:
Based on Time: to have the progress value reflect the amount of time spent (run time + setup time posted).
Based on Quantity: to have the value reflect the quantity of items finished in the operation (output quantity posted).
About Forecasting Functionality
Planning with/without Locations