Module 2 Configure production prerequisites

Case study 1A Discrete, Process and Lean manufacturing features

Exercise #1: Update the production control parameters

When you are starting to use the Production control module, you are required to do some configurations that will help the system operate according to your design and process design

The Operations manager at USMF, wants to make some changes to the policies so everything runs more efficiently. He wants to be sure routes are not allowed to be modified or have their approvals removed. In order to accomplish this, a new route operation should be created, and the effective dates updated.

Can you help the operation manager to perform this?

You will have to do the following:

Update the production control parameters

Steps

Go to Production control > Setup > Production control parameters.
Set the Block removal of approval slider to Yes under the Routes group.
Set the Block editing slider to Yes under the Routes group.
Select Save.
Close all pages.

Exercise #2: Create new production pools

USMF has been getting reports from the customers that orders are not arriving on time and that some of the delivered orders are missing pieces. One of the supervisor wants you to determine what is causing these problems so the company can find a solution.

You decide that you want more visibility into production orders that are delayed, and you want to track subcontracted production orders that are missing deliveries, production orders with missing materials and orders that are delayed due to machine failures.

How would you perform this?

You will have to do the following:

Production pool for Delayed sub contracted work
Production pool for missing materials
Production pool for machine failures

Steps

Create a production pool for delayed subcontracted work

Open Production control > Setup > Production > Production pools.
Select New to create a new pool.
Enter or select Delay-Sub in the Pool field.
Enter or select Subcontracted Work Delayed in the Name field.

Create a production pool for missing materials

Select New to create a new pool.
Enter or select MATMISSING in the Pool field.
Enter or select Materials Missing in the Name field.

Create a production pool for machine failures

Select New to create a new pool.
Enter or select MACHFAIL in the Pool field.
Enter or select Machine Failure in the Name field.
Select Save.
Close all pages.

Exercise #3: Create and manage resources

Company USMF has bought a new packing robot that will reduce the need for manual labor in the speaker packing workshop.

Workers from this group can therefore be reassigned to perform other work as the new robot becomes fully operational.

You were asked to add the robot as a resource

How would you perform this?

You will have to do the following:

Create capabilities
Assign resource to capabilities
Assign capabilities to a resource

Steps

Create capabilities

Go to Organization administration > Resources > Resource capabilities.
Select New from the Navigation bar.
Enter or select GTL-Assembly in the Capability field and Assembly in the Description field.
Select New.
Enter or select GTL-Packing in the Capability field and Packing in the Description field.
Close the Resource capabilities page.

Assign resources to capability

Go to Organization administration > Resources > Resource capabilities.
Select GTL-Assembly from the list of capabilities.
Select Add from the toolbar.
Select 5110, Assembly worker 1, in the Resource field.
Accept the default Expiration date of Never.
Enter or select 1 in the Priority field.
Accept the default Level of 0.00.
Repeat steps 3 to 7, for the resource 5111 and select Save.
Close the Resource capabilities page.

Assign capabilities to a resource

Go to Organization administration > Resources > Resources.
Select resource 5111 in the grid.
Expand the Capabilities FastTab.
Select View > All from the toolbar.
Select Add from the toolbar.
Enter or select GTL-Packing in the Capability field.
Accept the default Effective date of today's date.
Accept the default Expiration date of Never.
Accept the default Level of 0.00.
Enter or select 2 in the Priority field
Close the Resources page.

Exercise #4: Create an operation, assign relations and create a route

The company you are consulting has decided to produce a series of ebooks for a client.

The production manager at USMF, wants to create an operation for the finished good, assign relations, and create a route

Can you help the production manager?

You will have to do the following:

Create and configure an operation

Steps

Go to Production control > Operations > All routes.
Select New.
In the Name field, enter or select eBook route.
In the Item group field, enter or select TV&Video.
Select Save.
Select Route on the Action Pane then in the Maintain group, select Route details.
Select New.
In the Operation field, enter or select Assembly.
In the Scrap Percentage field, enter 20.
In the Link type field, select Soft.
Select New.
In the Oper. No. field, enter 20.
In the Operation field, enter or select Padding.
In the Scrap percentage field, enter 30.
In the Link type field, select Hard.
Select New.
In the Oper. No. field, enter 30.
In the Priority field, select Primary.
In the Operation field, enter or select Packing.
Refresh the page.
Select Save.
Close all pages.

NOTE The message bar may appear with a message that states, "There exist no relation for operation Padding.” The route contains the order of operations and the assignment of operations will occur in the next steps.
Go to Production control > Setup > Routes > Operations.
Select New.
In the Operation field, enter or select eBook.
In the Name field, enter or select eBook assembly.
Select Relations.
Select New.
In the Route group field, enter or select Discrete.
Expand the Setup section.
In the Formula field, select Capacity.
In the Costing resource field, enter or select 1211. A dialogue box appears informing that the default time and cost values from the costing resource will be inserted. Select Yes to continue.
In the Route relation field, enter or select eBook route created in previous steps and Route code should be set to Route.
Select Save.
Close all pages.

Exercise #5: Create a simple BOM without a version

You have been asked to assist the product designer at USMF and show her how to create a simple BOM for a new light cabinet.

You will approve the BOM using employee 000020, Julia Funderburk.

You will use the parameters on the right

Name: Light Cabinet
Item group: Audio
Site: 1pa
Item:
M0005 Enclosure
M0006 Binding posts
P0002 Speaker Damping Foam
Quantity for each item: 1

You will have to do the following:

Create a simple BOM

Steps

Go to Product information management > Bills of materials and formulas > Bills of materials.
Select New.
In the Name field, enter or select Light Cabinet.
In the Site field, enter or select 1.
In the Item group field, enter or select Audio.
Select Save.
In the Bill of materials lines section, select New.
In the Item number field, enter or select M0005.
Select New.
In the Item number field, enter or select M0006.
Select New.
In the Item number field, enter or select P0002.
Select Bill of materials on the Action Pane then in the Maintain group, Select Approval and choose 000020, Julia Funderburk.
Select OK.
Select Save.
Close all pages.

Exercise #6: Create a BOM in the BOM designer (Bonus)

The new product designer at USMF has received a new specification for the enclosure side of a cabinet.

She has requested your assistance.

You see that an item is not set up for this specification, so you only need to create a simple BOM with component lines.

Use employee 000020, Julia Funderburk, to approve the BOM.

Create a BOM titled “High Quality Speaker” and assign it to the Audio item group at site 1. Use the BOM designer to add items with warehouse 11 and the following quantities:

1 qty of M0008/High End Cabinet/Black
2 qty of M0002/Mid-Range Speaker Unit
1 qty of M0009/Protective Corners

You will have to do the following:

Create a BOM in the BOM designer

Steps

Go to Product information management > Bills of materials and formulas > Bills of materials.
Select New.
In the Name field, enter or select High Quality Speaker.
In the Site field, enter or select 1.
In the Item group field, enter or select Audio.
Select Bill of materials on the Action Pane then in the Maintain group, select Designer.
Select BOM lines on the Action Pane.
Select Add to component BOM.
In the list, find and select M0008 / High End Cabinet / Black.
Select OK.
Select BOM lines.
Select Add after line.
In the list, find and select M0009 / Protective Corners.
Select OK.
Select BOM lines.
Select Add before line.
In the list, find and select M0002 / Mid-Range Speaker Unit.
Select OK.
Close the Designer page.
Refresh the Bill of materials page. This will populate the previously created BOM formula lines.
In the list of Bill of materials lines, find and select the row for M0002 / Mid-Range Speaker Unit.
Set Quantity to 2.0000.
In the Action pane, select Approval in the Maintain group in the Bill of materials tab.
Select 000020, Julia Funderburk.
Select OK.
Close all pages.

Exercise #7: Create a BOM with a version

The sales department has reported that there is a high demand for rosewood colored speakers instead of the traditional black.

You are asked to prepare for the manufacture of more rosewood colored speakers by creating a version, making a copy of the existing BOM, removing item M0008/High End Cabinet/ Black and add item M0008/High End Cabinet/Red for a quantity of 1.

Employee 000020, Julia Funderburk must approve the version.

Do not activate the BOM because the item is not ready for use yet.

Use the specifications given at right

Item number: 72708
Item name: High Quality Speaker Rosewood
Item group: Audio
Item model group: FIFO
Storage Dimension group: SiteWH
Tracking Dimension group: None
Warehouse 11
Approved by: 000020, Julia Funderburk

You will have to do the following:

Create a BOM with a version

Steps

Go to Product information management > Products > Released products.
Select New.
In the Product number field, enter or select 72708.
In the Product name field, enter or select High Quality Speaker Red.
In the Item model group field, enter or select FIFO.
In the Item group field, enter or select Audio.
In the Storage dimension group field, enter or select SiteWH.
In the Tracking dimension group field, enter or select None.
Select OK.
On the Action Pane, select Manage inventory.
Select Default order settings.
In the Default order type field, select Production.
Under the Inventory FastTab, In the Default warehouse field, enter or select 11.
Close the page.
On the Action Pane, select Engineer.
Select Designer.
Select BOM.
Select Create version.
In the Name field, enter or select High Quality Speaker Rosewood.
Select Yes in the Copy field.
In the Site field, enter or select 1.
Select OK.
In the Item number field, enter or select D0004.
Select OK.
In the tree, select Item number: 72708\M0008 / High End Cabinet.
Select BOM lines.
Select Delete.
Select BOM lines.
Select Add before line.
In the list, find and select M0008 / High End Cabinet / Rosewood.
Select OK.
In the tree, select Item number: 72708.
Select BOM.
Select BOM versions.
Select Approval. Select 000020, Julia Funderburk.
Select Yes in the Do you also want to approve the bill of materials? field.
Select OK.
Close all pages.

Exercise #8: Create a production order

The minimum information required to create a production order is an active bill of materials.

Create a new production order to test the previously created BOM

You will have to do the following:

Create a new production order

Steps

Go to Production control > Production orders > All production orders.
Select New production order.
In the Item number field, enter or select 72708.
In the Site field, enter or select 1.
Set Quantity to 10.00.
In the Time field, enter 10:15 AM.
Select Create.
Select the Production order tab in the Action Pane, then in the Process group, select Estimate.
Select OK.
Select Release.
Select OK.
Select Start.
Select OK.
Select Report as finished.
Select OK.
Select End.
Select OK.
Close all pages.

Exercise #9: Start a discrete production order (Bonus)

You can get production orders either manually created or firmed from the Master planning with status “Scheduled”

The production of the ash enclosure back sides of the speakers is ready to be started.

The production supervisor wants to use the start form and select a production order with status of “Scheduled” to start.

Can you help the production manager to perform this?

You will have to do the following:

Start a discrete production order

Steps

Select Production control > Production orders > All production orders.
Select any production order with the production order status set to Scheduled (for example, P000191).
On the Production order action pane, select Start.
On the Overview tab, in the Quantity field, enter the quantity 2.00 of the production order to produce.
In the Date field, enter today’s date for the date that the production starts.
Uncheck the Start production check box.
Select OK.
Close all pages.

Exercise #10: Run a resource schedule

The Production Manager wants to use a newly purchased assembly robot to increase flexibility in production.

In the past, when she designed the production process (route) for a product, she had to specify where each operation was to be performed.

Now, she want to defer the allocation of where and by whom an operation is performed until the production is scheduled, and to use excess capacity in other workshops to eliminate bottlenecks in heavily loaded workshops.

She is not sure how to do so and asked for your help.

Can you help?

You will have to do the following:

Create capabilities and resources
Identify the resources applicable for the operation
Add requirements for a capability to an operation

Steps

Create capabilities and resources

Navigate to Organization administration > Resources > Resource capabilities.
Select New.
Enter or select 20 in the Capability field and Assembly in the Description field.
Select New.
Enter or select 30 in the Capability field and Packing in the Description field.
In the Resources FastTab, select Add.
Select 1222 (Speaker packing worker 1) in the Resource field.
Accept the default expiration date of Never.
Accept the default Level of 0.00.
Enter or select 1 in the Priority field.
Close the Resource capabilities form.
Open Organization administration > Resources > Resources.
Select New.
Enter or select 000727 in the Resource field.
Enter or select Assembly robot in the Description field.
Accept the default of Machine in the Type field.
In the Capabilities FastTab, select Add.
Select 20 in the Capability field.
Accept the default expiration date of Never.
Accept the default Level of 0.00.
Enter or select 1 in the Priority field.
Expand the Resource groups FastTab.
Select View > All.
Select Add.
Enter or select 1210 in the Resource group field, enter or select the next working day in the Effective field, and then accept the default expiration date of Never.
Accept the default Input warehouse.
Accept the default Input location.
Scroll up, expand the Calendars tab, and select Add.
Select 24hr in the Calendar field and then accept the default expiration date of Never.
Close the Resources form.

Identify resources applicable for the operation

Navigate to Production control > Operations > All routes
Select route 000002 (STANDARD SPEAKER - D0003) by selecting on the link for 000002.
Select the Route tab in the Action pane, then in the Maintain group, select Route details.
Verify operation 10 is selected in the top grid of the Route form.
In the bottom grid, select Applicable Resources.
Notice that all the resources from the 1210 resource group are listed.
Scroll one day forward by selecting the Next day button or choose the date picker field.
Select OK. This closes the Applicable resources form.

To add requirements for a capability to an operation, follow these steps:

In the Route details form for route 000002, with operation 10 selected in the top grid, select the Resource requirements tab on the bottom grid.
In the Resource requirements grid, select the line where Requirement type is Capability and Requirement is Assembly.
Select Delete.

Note A message box will appear to confirm the action. Choose Yes to delete the record.
Select Maintain resource requirements. This starts the wizard.
On the Welcome screen, select Next.
On the Search criteria screen, select Capability in the Requirement type field.
Enter or select 20 in the Requirement field.
Accept the default option for resource requirements on activity.
Select Next.
On the Action screen, leave the defaults and select Next.
On the New resource requirements screen, set Requirement type to Capability, Requirement to 20, and check the Operation scheduling and Job scheduling check boxes.
Select Next.
On the summary screen, review your options and choose Finish.
Close all pages.

Exercise #11: Configure costing policies

At USMF, you need to set profit-settings to help sales personnel calculate an accurate sales price after considering all costs for cabinet item D0002.

You should also be able to view the costing sheet to analyze the cost breakdown

Can you help the sales personnel?

You will have to do the following:

Update the profit settings on the item
Review the costing sheet setup
View the calculation details on the item

Steps

Go to Product information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of D0002.
In the list, select D0002 to open the details page.
Expand the Manage costs FastTab.
Select M9 cost group to open the cost group details page.
Select Edit.
Set Profit percentage to 40.00.
Select Add.
In the Profit-setting field, select Profit 1.
Set Profit percentage to 70.00.
Select Save.
Close the page.
On the Action Pane, select the Engineer tab.
In the BOM group, select BOM versions.
Under the Bill of materials lines, select M0005 to open the Product information dialog.
Select M0005 item number (not product number) to open the Released product details page
Select Cost group M2 in the Manage costs FastTab to open the Cost group details page.
Select Edit.
Set Profit percentage to 30.00.
Select Add.
In the Profit-setting field, select Profit 1.
Set Profit percentage to 60.00. Select Save.
Close the page.
Close all pages.
Go to Cost management > Indirect cost accounting policies setup > Costing sheets.
In the tree, select Root\Cost of Conversion\COC-Material\COC - M2 - Cabinets comp.
Review the structure of the costing sheet.
In the tree, select Root\Cost of Conversion\Overhead on Conversion\COC - OVH4 - Labor overhead\Indirect labor cost - Rate per process time.
Review the Absorption basis, and Rate FastTabs values.
In the tree, select Root\Cost of Conversion\Overhead on Conversion\COC - OVH4 - Labor overhead.
Select OVH4.
Set Profit percentage to 80.00. Select on Save.
Close all pages.
Go to Product information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of D0002.
Select the D0002 link to open the Released product details page.
On the Action Pane, select the Manage costs tab.
In the Set up group, choose Item price.
Select the Pending prices tab.
Select Calculate item cost.
In the Costing version field, enter or select 10.
Select OK.
Select View calculation details.
Select the Costing sheet tab.
Analyze the cost breakdown for the cabinet D0002.
Close all pages.

Exercise #12: Configure manufacturing execution (Bonus)

The Production Manager determined that the best way to post picking lists is to use the operation quantity feedback (backflush on operations) method.

If the actual consumption on BOM items differs from the estimated consumption, the employee can enter the actual item consumption when providing quantity feedback

The production manager not sure how to perform this and asked for your help.

Can you help?

You will have to do the following:

Update the parameters under manufacturing execution production order default parameters

Steps

Open Production control > Setup > Manufacturing execution > Production order defaults.
On the Start tab, select Status in the Update start on-line field.
In the Automatic BOM consumption field, select Never.
Select the Operations tab.
Set the Setup option to No.
In the Automatic BOM consumption field, select Always.
Select the Report as finished tab.
In the Update finished report on-line field, select Quantity.
In the Automatic BOM consumption field, select Never.
Close the Production order defaults form.

Exercise #13 - Configure automatic route consumption on setup jobs (Bonus)

Your estimation on operation setup has proven accurate, so the Production Manager decided that it is not necessary for employees to register on setup jobs.

The time consumption on setup jobs must be posted automatically

How would you automate this posting?

You will have to do the following:

Update routing groups.
Update the routing group on the MES production order defaults

Steps

Open Production control > Setup > Routes > Route groups.
From the list, select Sfc Shop Floor Control Routing Group.
Select Edit.
On the General FastTab, in the Automatic route consumption group, enable the Setup time field.
Close the Route groups form.
Open Production control > Setup > Manufacturing execution > Production order defaults.
On the Start tab, in the Automatic route consumption field, select Route group dependent.
Enable the Post route card now field.
Close the Production order defaults form.

Exercise #14: Use manufacturing execution (Bonus)

To proceed with testing the manufacturing execution, you need to enable time registration for Shannon, the machine operator in USMF.

Shannon needs to use the job card terminal to control the execution of the production order

Can you enable the time registration? How?

You will have to do the following:

Enable time registration for the machine operator

Steps

Go to Human resources > Workers > Employees.
Use the Quick Filter to filter on the Name field with a value of Shannon.
Select Activate on registration terminals in the Time tab of the action pane.
In the Calculation group field, enter or select Man.
In the Default calculation group field, enter or select Man.
In the Approval group field, enter or select AdmMan.
In the Standard profile field, enter or select Standard.
In the Profile group field, enter or select Man.
Set the Use timecard toggle to Yes.
In the Configuration field, enter or select Production.
Set the Supervisor options toggle to Yes.
Select OK.
In the list, select Shannon Dascher to view the Employees details page.
Select the Time registration tab.
Select Edit.
In the Badge ID field, enter or select 069.
Select Save.
Close the page.
Go to Production control > Manufacturing execution > Job card device.
In the Personnel number field, enter or select 069.
Select Log in.
Select Start job.
Set Quantity to start to 1.00.
Select OK.
Select Report progress.
Set Error quantity to 1.00.
In the Error cause field, select Material.
Select Complete.
Select Break.
In the list, select break from work.
Select OK.
Select Stop break.
Select Activity.
In the list, find and select Equipment repair
Select OK.

Note A message may appear stating, “You are currently registered on other jobs(s). You need to report feedback on these before commencing on new jobs.’’
Select OK.
Set Error quantity to 2.00.
In the Error cause field, enter Machine.
In the Job status field, select Stopped.
Select Complete.
Select Next job.
Select Previous job.
Select Report progress.
Set Good quantity to 5.00.
In the Job status field, enter Completed.
Select Complete.
Close the page.