manufacturing and shop floor control in infor ln
TRANSCRIPT
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Manufacturing and Shop Floor Control
MFG- SFC-01
ERP LN
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a
Chapter 0 –Getting Started
Manufacturing Master ata
!ersion
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Course Goals
Define Item Data for Manufactured Items
Create work centers and warehouses for manufacturing
Define Bills of Material and Routings
Calculate Cost Prices for items
Define Calendars and Periods for use in Shop FloorControl
Understand Unit Effectiit! for Production "rders Create Production "rders and Process orders
#ppl! Masks$ Seriali%ed Items$ and &ot Control toProduction "rders
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Course "#$ecti%e
Proide an understanding of the application$
functionalit!$ and e'ecution of the master data and
production order process for the Manufacturing
package(
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Prere&uisites
Before attending this course$ participants should haecompleted)
ERP&* +e,top *aigation
ERP&* Common Data
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Education Le%els
Na%igation and Co''on ata
Pac(age Specific )*+E 'anufacturing
,d%ancedProduct
or(shops
,d%anced.Product-specific
/noledge
General
ERPLN/noledge
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Course Methodolog
Lecture and iscussion
234
5ands-onPractice
304
MeasureResults
34
Practical E6ercises
e'onstrations
,pplicationof Concepts
7usinessConcepts
Re%ie 8uestions
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Manufacturing Master ata
Manufacturing and Shop Floor Control
ERP LN
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"#$ecti%es
Define Item Data
Create Entities for Manufacturing Module
Define Bills of Material and Routings
Define Calendars and Periods
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*te' Structures
Item data
Bill of Material
Routing
Cost Price Calculation
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Plan ite' data
-eneral Data
Item or Product famil!
Default suppl! source
production
purchase
distri,ution
Planning hori%on
.ime fence
Forecast time fence
Planning /ori%on
"rder /ori%on
Master plan
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*te' ash#oard
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*ew work center t!pe) cost work center Fle'i,le work center selection after free%ing estimates 0also for ad
hoc su,contracting1
2 Costing workcenter collects costs related to
operations
2 Calculation "ffice collects costs$ results$
surcharges related to an production order
2 Costing workcenter collects costs related to
operations
2 Calculation "ffice collects costs$ results$
surcharges related to an production order
Costing 9 Planning or( centers
+C3 +C4
+C5 Cost or( center
Planningor( centers
Fle6i#leselectionforproduction
order planning
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*te' structures*te' Production ata
B"M Unit 6 .he num,er of manufactured items which theB"M relates to(
Scrap Factor 6 .he percentage of an item e'pected to ,elost during the manufacturing process(
Scrap 7uantit! 6 .he actual num,er of items e'pected to,e lost during the manufacturing process(
Routing Unit
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7ill of Material
2&ist of components for the main item(
2&ists the 8uantit! of each component
re8uired to ,uild the main item(
2Ma! ,e multi6leel containing other
manufactured items with B"M9s
efinition
# Bill of Material is a listing of all
components and releant data 0su,6
assem,lies and raw materials1 that comprise
a manufactured item( .he B"M esta,lishes
the parent6child relationship ,etween a
manufactured item and its components(
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7ill of Material
2Position lists the components
2Defines 7uantit! re8uired
2:oom in and %oom out capa,ilit! from Specific Menu
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7i(e
7ill of MaterialSingle Le%el
Fra'e )1:heel );:
,Pos+10
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7ills "f Material'ulti-le%el
Components
Sub Assembly
Components
Level 1 - Sub Assemblies (Manufactured or Purchased)
Level 2 - Components (Purchased nly)
Level ! - "inished Product (Manufactured nly)
Sub Assembly
"inal Assembly
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Loops in Production 7"Ms
C5,*R+==
SE,>+==SE,>
8>?1
7,C/+==7,C/
8>?1
P@RC5,SE
FR,ME+==
FR,ME
8>?;
F,7+0002
F,7R*C
8>?0+3
F*=+"""1
,5ES*!E
8>?0+1
F*=+"""1
,5ES*!E
8>? 0+;
F,7+0001
F",M
8>?1
R,-+""";
S>EEL >@7E
8>?;+0
F,7+0002
F,7R*C
8>?0+A
F,7+0001
F",M
8>?1
R,-+""";
S>EEL >@7E
8>?B+0
F*=+"""B
7"L>S
R,-+""";
S>EEL >@7E
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Routings
efine an 'achines used
Machines
)tirou010;'000:
efine the %arious tas(s
>as(s
)tirou010B'000:
efine the routing codes per ite'
*te's - Routings)tirou1101'000:
efine the operations per routing
Routing "perations
)tirou110;'000:
efine the or( centers
or( Centers
)tirou0101'000:
Start
End
Routings)
Determine how to ,uild the main item
Define the re8uired operations
re8uired to ,uild the main item(
Define which work centers and which
machines are inoled with the
manufacturing of the end item(
Indicate the time re8uired to complete
each operation(
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RoutingCo'ponents of an "peration
or(Centers Machines
>as(s
"peration
5 n
5
n m
n
5
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Routing Setup
Machine
#or$ Centers
Basic Components
%outin& code
%outin& per routin& code
'as$s
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Routing"perations
Saing elding
,sse'#ling
Routing Fra'e
Routing 7i(e0+3 hrs 0+B hrs
1+0 hrs
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Routing>pes
drillin& assembly
efault routin& p to *uantity
+++++++
drillin& Line 1
Line 2
,ty dep %ou
p to *uantity
1!!!!!+++++++
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Routing>pes
drillin&
assembly
paintin&
Standard
routin&
drillin&
assembly
paintin&
.tem
specif ic
routin&
/ item A / item 0 / item C / item
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Routing "perations
"peration *um,er
Step si%e
Operation
10
Operation
30
Operation
40
Operation
60
Operation
50
Operation
20
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Routing "perations
Routing Code and Item create a uni8ue com,ination ofoperations(
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Calendars and Periods
Calendar 5ierarch
Calendars are selected for use ,ased on a prescri,ed hierarch!(
For the +ork Center the order of searching for a alid calendar is)
Calendar attached to the Department that e8uals the +ork Center
Calendar attached to the Enterprise Unit of the of Department
2Compan! Calendar 0from the Companies session
tcemm55;
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Calendar Flo
efine the a%aila#ilit tpes+
,%aila#ilit >pes
)tcccp0101'000:
efine or(ing 5our tpes
or(ing 5our >pes
)tcccp010B'000:
efine Calendar Codes for ne
calendar
Calendar Codes
)tcccp0110'000:
Lin( ,%aila#ilit >pes to calendar
Calendar ,%aila#ilit >pes
)tcccp0130'000:
Stop
Start
efine the a%aila#ilit tpes for the
Standard Calendar for each da of
the ee(+Standard Calendar
)tcccp00120'000:
@pdate Calendar to effect changes
@pdate Calendar
)tcccp0;;'000:
efine Calendar e6ceptions
Calendar or(ing 5ours
)tcccp01;0'000:
Lin( Calendar to resource
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Re%ie 8uestions and ,nsers
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Guided >as(D title
Step 5(
Step 3(
Etc(
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Lesson ; – *te' Control
Manufacturing and Shop Floor Control
ERP LN
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"#$ecti%es
#fter completing this lesson !ou will ,e a,le to)
2Identif! Master Data and Parameters for Unit Effectiit!
2Define effectiit! Units2Identif! Item Effectiit! Re8uirements
2Define Mask Data
2Create Seriali%ed and &ot Control Items
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@nit Effecti%it
efine the para'eters for @nit
Effecti%it+
@nit Effecti%it Para'eters
)tcuef0300'000:
Create ite's for @nit Effecti%it
*te's - General
)tci#d0301'000:
efine the Effecti%it @nits
Effecti%it @nits
)tcuef030;'000:
Stop
Start
Create Effecti%it Series
*te's - Effecti%it Series
)tcuef0101'000:
,ppl @nit Effecti%it to
Production. Sales. or Planning
efine an e6ceptions to the
re&uire'ents
E6ceptions
)tcuef0103'000:
efine the %arious re&uire'ents
Re&uire'ents
)tcuef010'000:
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+hat does Unit Effectiit! offer =
Model > Use modifications and ariations in E6B"M$P6B"M$ R"U$ Sourcing Strategies$ Item PurchaseData( 0a &ean Configurator of the production process1
Pegging all Materials to Sales "rders
@nit Effecti%it
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Effectiit! Unit 0num,er1
#n ID for a specific model ? ariation of an end Item 0used for configuringthe product structure1
# peg to a sales order line 0used for tracking and tracing of materials1
E'ception
&inked to an @o,Aect9 0 record in B"M$ R"U$ Sourcing Strateg!$ etc ta,le1
Defines if B"M6line$ etc( is alid or not for a specific EU
Is used to @customi%e9 processes like B"M6e'plosion$ Selection of SourcingStrateg!
0@e'plode B"M of item B for Effectiit! Unit 5
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7ill of Material )1:
,
C;C17
Standard production of ite' , D use co'ponents 7 and C1
)ithout effecti%it unit:Specific production of ite' , D use co'ponents 7 and C;)for effecti%it unit 666H:Specific production of ite' , D use co'ponents 7. C1 and C;)for effecti%it unit H:
Unit Effectie
B"M lines
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Routing and "perations );:
,
C;C17
Routing 001Doperation 10 )asse'#l:operation ;0 )finishing:operation B0 )paint red:
Standard production of , D use operations 10 9 ;0)ithout effecti%it unit:Specific production of , D use operations 10. ;0 and B0)for effecti%it unit 666H:
.he routing 0instead of the indiidual operations1
can ,e unit effectie
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Mas(s
efine the 'as(s that ill #e used
Mas(s
)tci#d210;'000:
efine the seg'ents that ill 'a(e
the 'as( code
Mas( Seg'ents
)tci#d230B'000:
Stop
Start
efine the >ranslation >a#les
>ranslation >a#les
)tci#d2302'000:
?es
No
@se >ranslation>a#lesI
efine the >ranslation >a#le!alues
!alues # >ranslation >a#le
)tci#d210'000:
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SerialiJed ite's concept
Seriali%ed items replace lot ,! unit of SS# Baan I0or SS# SS# ERP (
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SerialiJed ite's para'eters
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Register Serials during ,s #uilt )1:
If alue is es$ the registration of the serial num,ers used inproduction is carried out onl! in the Serial End Item - As-BuiltComponents
session G it is regarded as part of the manufacturingprocess(
If the alue of this field is *o$ the serial num,ers are recorded themoment the components are issued from the warehouse(
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Lesson B – Cost Price ata
Manufacturing and Shop Floor Control
ERP LN
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Cost Price Calculation
Lesson ObjectivesAfter completin& this lesson you 3ill be able to4
— Set up cost prices(
— iew cost price parameters(
— Define cost components(
— Create operation rate codes(— Define price calculation codes(
— Define cost price calculation data(
— Define an operation rate(
— #dd an item surcharge(
— Define su,contracting rates(— Define item surcharges for an item(
— Simulate a purchase price for an item(
— Calculate the cost and the aluation price for an item(
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Cost 7rea(don to Produce *te'
Material K 0
0,ased on
Bill of Material
and item data
"%erhead K 10
0,ased on
Item data$ Routing
and Bill of Material
La#or K 30
0,ased on
Bill of Material
and Routing
>otal *te' Cost K 1;0
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Entering Re&uired *nfor'ation
Maintain Cost Price
Co'ponents
Maintain Cost Price
Ccalculation Codes
Maintain "peration
Rate Codes
Maintain CPR
Para'eters
Maintain Si'ulatedPurchase Prices
Maintain Cost Price
Calculation Codes
Maintain 7"M
Maintain *te' ata
Maintain "peration
Rates
Maintain or( Centers Maintain >as(
Maintain Surcharges
# *te'
Maintain Surcharges
# *te' Group
Maintain
Su#contracting Rates
Maintain Routing
Calculate Cost Prices
Maintain Surcharges
# *te'
Maintain Surcharges
# *te' Group
"peration Costs
Para'eter ependent
"R
"R
*f operation is
su#contracted
"R
Material Costs
Purchased *te' Manufactured *te'
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Cost Price Master ata
efine Cost Price Para'eters
Cost Price Calculation
Para'eters
)ticpr0100'000:
efine Cost Co'ponets used to
capture costs
Cost Co'ponents
)tc'cs012A'000:
Set up Cost Co'ponent charts
Cost Co'ponent Charts
)ticpr010'000:
Start
End
efine "peration Rate Codes
"peration Rate Codes
)ticpr0130'000:
efine Price Calculation Codes
Price Calculation Codes
)ticpr1100'000:
@se Chart
etails ?es
No
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CPR Para'eters
Define the Standard PriceCalculation Code(
Determine if Fi'ed Costs
are applied(
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Cost Price >er's
Cost Components: Used to categori%e production costsinto specific groups called cost t!pes(
Operation rate codes: Used to categori%e la,or$ machine$oerhead$ and su,contracting costs associated with the
production of an item(
Price calculation codes: Used to define how a cost orsales price is calculated( "ne is used for costingpurposed and all others are simulation codes(
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Price Calculation Codes
Determines the priorit! of the purchase price
calculation for purchased items(
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Price Calculation Codes
— Si )Si'ulated Purch+ Pr+:) # price calculationcode can ,e created and used to simulate a
purchase price( .hese prices are for a uni8ue item
and cost price calculation code in the Simulated
Purchase Prices 0ticpr5;
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Cost Price Calculation
Calculate the standard cost for anite'
Caclulate Cost and !aluation
Prices)ticpr;;10'000:
@pdte the standard cost price
,ctualiJe Cost and !aluationPrices
)ticpr;;;0'000:
Start
Print 'ultile%el cost prices
Print Multile%el Cost and !aluationPrices
)ticpr;2;0'000:
End
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Cost Price s aluation Price
2 B! price calculation code
Based on the structure information
2 Situation independent) ,! logistic compan!
2 Simulation?#nal!sis purposes
2 Fie aluation methods
2 Based on actual purchase or production cost
2 Situation dependent) inentor! alue$ issue$
receipt$ transfer
2 Inentor! aluation > financial accounting
Cost Price !aluation Price
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!aluation 'ethods
Last in First out )L*F":First in First out )F*F":Mo%ing a%erage unit cost )M,@C:
Lot costing
Fi6ed transfer price )F>P:
,ctual%aluation
'ethods
Esti'atedin%entor %alue
7aan 2
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Lesson 2- Shop Floor Control
Manufacturing and Shop Floor Control
ERP LN
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"#$ecti%es
Lesson "#$ecti%es
#fter completing this lesson$ !ou will ,e a,le to)
2Define Default Production "rder Data
2Define Production "rder date
2Create Production "rders
2Issue Production "rder Materials
2Process Production "rders
2Understand Production "rder Costing
2Create and Process Unit Effectie "rders
2Process Su,contract Production orders
P d i " d S
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Production "rder Status
.he status of the production order determines
the actions that can ,e performed on the
production order( .he aaila,le production
order status9s are)
2Planned
2ocu'ents Printed
2Released
2,cti%e
2>o 7e Co'pleted2Co'pleted
2Closed
2,rchi%ed
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Shop Floor Control"rder Grouping
#ctiities ,! "rder -roup)SFC
Print Production "rder Documents
Release Production "rders
Report "rders Completed -lo,all!
Backflush Materials and /ours
Cancel Production "rders
Print Inentor! ,! Production "rder
Print Shortages ,! Production "rder
Utili%ation Reports Update Ph!sical &ocation
Report "perations Complete -lo,all!
arehousing
Process "ut,ound #dice
-enerate "ut,ound #dice
Release "ut,ound #dice
-enerate Picking &ist
Enterprise Planning
Confirm planned production orders
transfer planned production orders
Se%eral Reporting Sessions
7 i P d ti " d Fl
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7asic Production "rder Flo
Create a production order ith
su#contract operation included
Production "rders
)tisfc0301'000:
Release Production "rders
Release Production "rders
)tisfc0;02'000:
Report operations co'pleted for
Production "rders
Report "perations Co'pleted
)tisfc01B0'000:
Report Production "rders
co'pleted
Report "rders Co'pleted
)tisfc030;'000:
Stop
Start
*ssue production order co'ponent
'aterials
Material to *ssue for
Production "rders
)ticst1301'000:
Basic Process for
Production "rders
P d ti " d
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Production "rders
Can enter orders manuall!$ or iew orders that hae
,een transferred to Shop Floor Control
R l P d ti " d
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Release Production "rders
+hen !ou release a production order$ the s!stem
performs the following actions)
2+arehousing orders are created in +arehouse
Management( .hrough these warehousing orders$ theissue of materials and receipt into inentor! of end
products are handled(
2 #llocations of materials are moed to the shop floor
warehouse(
2Inspection orders are created in 7ualit!Management if applica,le(
Production orders can #e released # using theRelease Production "rders tisfc0;02'000:session+
M t i l * f P d ti " d
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Material *ssue for Production "rders
.he Direct Process +arehouse "rder &ine check ,o' in the Items G
Production 0tiipd
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Esti'ated Materials
Before a production order is released the Estimated Materials 0ticst
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*ssuing Materials
ou can onl! change the 8uantit! if the
production order has one of the following
statuses)
— Released
—
#ctie
— .o ,e Completed
— Completed
7ac(flushing
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7ac(flushing
7ac(flushing
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7ac(flushing
7ac(flushing
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7ac(flushing
Su#contract Production "rders
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Su#contract Production "rders
Su,contracting is the use of outside ,usiness partners to
complete specific operations or serices for !our production
process that !ou ma! not ,e a,le to coer from a capacit!
standpoint or are not capa,le of e'ecuting in house(
.wo t!pes of su,contracting can ,e performed(
— Unplanned su,contracting) "perations of a production
order are su,contracted in the Su,contract "perations session(
.he su,contracting costs are part of the estimated and?or actual
production order costs(
— Planned su,contracting) +ork centers of the Su,contract
+ork Center t!pe are attached to the item routing and include a
Su,contracting Rate and task( .he e'pected su,contracting
costs are part of the standard cost price(
Su#contracting "rder Flo
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Su#contracting "rder Flo
efine #usiness partner for
su#contracting
7usiness Partners
)tcco'2300'000:
efine a Su#contract or( Center
or( Centers
)tirou0301'000:
Create a su#contracting tas(
>as(s
)tirou010B'000:
Lin( su#contracting #usiness
partner and tas( to a rate
Su#contracting Rates)ticpr110'000:
efine su#contracting ite'
General *te' ata
)tci#d0301'000:
Start
Lin( su#contracting tas( to ite'
routing
Routing "perations
)tirou110;'000:
Continued
Continue
Create a production order ith
su#contract operation included
Production "rders
)tisfc0301'000:
Release Production "rders
Release Production "rders
)tisfc0;02'000:
,ppro%e Purchase "rder for
Su#contracting ite'
Purchase "rders)tdpur2300'000:
Recei%e the co'pleted
su#contracting goods
arhouse Receipts
)thinhB31;'000:
Su#contracting
"peations
Report operations co'pleted for Production "rders
Report "perations Co'pleted
)tisfc01B0'000:
Report Production "rders
co'pleted
Report "rders Co'pleted
)tisfc030;'000:
?ES
N"
Generate Purchase "rder for
Su#contracting ite'
Generate Su#contracting
Purchase "rders
)tisfc;;30'000:
Stop
7ac(flushing
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7ac(flushing
Shop efficienc
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p "rder Grouping
&a!er on production orders 0SFC1$ which groupsproduction orders ,ased on characteristics
E'ecute ,usiness procedures ,! "rder -roup
Reduction in process time for operations?orders reporting complete
-roup ID) 53SFC) 3 SFC)
SFC "rders -rouped SFC "rdersSFC) 5
SFC) 3
SFC) H
SFC)
SFC) 53
SFC) J
SFC)
SFC) 5 SFC) SFC) 53-roup ID) 534
SFC) H SFC) J
-roup ID) 53
Sh Fl C t l
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Shop Floor Control"rder Grouping
#ctiities ,! "rder -roup)SFC
Print Production "rder Documents
Release Production "rders
Report "rders Completed -lo,all!
Backflush Materials and /ours
Cancel Production "rders
Print Inentor! ,! Production "rder
Print Shortages ,! Production "rder
Utili%ation Reports
Update Ph!sical &ocation
Report "perations Complete -lo,all!
arehousing
Process "ut,ound #dice
-enerate "ut,ound #dice
Release "ut,ound #dice
-enerate Picking &ist
Enterprise Planning
Confirm planned production orders
transfer planned production orders
Se%eral Reporting Sessions
Sh Fl C t l
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Shop Floor Control "rder Grouping
Create EP order group
Confirm? transfer per order group Create SFC order group
-rouped SFC orders
-rouped planned orders
E'ecute actiities
,! order group
0related to SFC
procedure1
+arehouse
"ut,ound
and Picking
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Education
to Move
Forward, Faster
sa'ple #ullet slide
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sa'ple #ullet slide
First leel ,ullet$ 3H pt #rial roman sample te't continueshere and on
First leel ,ullet$ 3H pt #rial roman sample te't continueshere and on
Second leel ,ullet$ 3< pt #rial roman sample te't continues hereand on
Second leel ,ullet$ 3< pt #rial roman sample te't continues here
and on First leel ,ullet$ 3H pt #rial roman sample te't continues
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Sample su,head
*nstructor e'onstrationD title
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*nstructor e'onstrationD title
Step 5(
Step 3(
Etc(
Production "rders
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Production "rders
Definition$ Planning and Release of Production "rders
Production "rder Materials and Back flushing
Su,contracting of Production "rder 0"perations1
Production "rder Costing 0Materials$ "perations1) #ctual s(Planned
*ew)
Bu!?Make settings 0Date Eff( Item .!pe1
Shared work centers
Input?output control
"rder grouping Micro routing
sa'ple organiJation chart
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sa'ple organiJation chart
Kane Doe
Kane Doe Kane Doe Kane Doe
Kane Doe
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Kane Doe
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Kane Doe
sa'ple te6t and single &uote
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sa'ple te6t and single &uote
Section introduction
First ,ullet leel$ initial line cap$3< points$ #rial
First ,ullet leel$ initial line cap$3< points$ #rial
Section introduction
First ,ullet leel$ initial line cap$3< points$ #rial
First ,ullet leel$ initial line cap$3< points #rial
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nisl ut aliquip ex. Lorem
ipsum dolor sit cosectetuer
adipiscing.”
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