Module 3 Implement production methods

Case study 1B Discrete manufacturing

Exercise #1: 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 #2: 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 #3: 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 #4: 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 #5: 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 #6: 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.

Exercise #7: Create an approved vendor list and setting method to Warning Only (Bonus)

Contoso Orange Juice USP2 has determined that approved vendor control shall be placed on item M7001 with the approved vendor being US-113, and they have assigned the task to you

Can you perform this task?

You will have to do the following:

Set up the approved vendor or default vendor
Set vendor check method to Warning Only

Steps

Set up the approved vendor or default vendor

In USP2 (Navigate to upper right corner of window and change company from USMF to USP2), Go to Product information management > Products > Released products.
Use the Quick Filter to filter on the Item number field with a value of M7001.
In the list, select the item number M7001 to view the Released product details page.
On the Action Pane, select Purchase.
In Approved vendor group, select Setup.
Select Add.
In the Vendor field, enter or select US-113.
Select Save.
Close the page.

Set the vendor check method to Warning Only

On the Released product details page, select Edit.
Expand the Purchase FastTab, set the Approved vendor check method field from No check to Warning only.
Select Save.
Close the page.