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Manufacturing and Shop Floor Control

MFG- SFC-01
ERP LN

Chapter 0
Getting Started
Manufacturing Master Data
a
Version

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 Floor
Control
Understand Unit Effectivity for Production Orders
Create Production Orders and Process orders
Apply Masks, Serialized Items, and Lot Control to
Production Orders
3

Course Objective

Provide an understanding of the application,


functionality, and execution of the master data and
production order process for the Manufacturing
package.

Prerequisites

Before attending this course, participants should have


completed:
ERPLN Webtop Navigation
ERPLN Common Data

Education Levels

Advanced,
Productspecific
Knowledge

Advanced
Product
Workshops

Package Specific (I.E manufacturing

General
ERPLN
Knowledge

Navigation and Common Data

Course Methodology

Lecture and
Discussion
45%

Business
Concepts

Application
of Concepts

Demonstrations

Hands-on
Practice
50%

Practical Exercises
Measure
Results
5%

Review Questions

Manufacturing Master Data

Manufacturing and Shop Floor Control


ERP LN

Objectives

Define Item Data


Create Entities for Manufacturing Module
Define Bills of Material and Routings
Define Calendars and Periods

Item Structures

Item data
Bill of Material
Routing
Cost Price Calculation

10

Plan item data

General Data
Item or Product family

Default supply source


production
purchase
distribution

Planning horizon
Time fence
Forecast time fence
Planning Horizon
Order Horizon

Master plan

11

Item Dashboard

12

Costing & Planning work centers


New work center type: cost work center
Flexible work center selection after freezing estimates (also for ad
hoc subcontracting)
Costing workcenter collects costs related to
operations
Calculation Office collects costs, results,
surcharges related to an production order

WC1

13

Flexible
selection
for
production
order planning

Cost work center

Planning
work centers

WC3

WC2

Item structures
Item Production Data

BOM Unit - The number of manufactured items which the


BOM relates to.
Scrap Factor - The percentage of an item expected to be
lost during the manufacturing process.
Scrap Quantity - The actual number of items expected to
be lost during the manufacturing process.
Routing Unit

14

Bill of Material

Definition
A Bill of Material is a listing of all
components and relevant data (subassemblies and raw materials) that comprise
a manufactured item. The BOM establishes
the parent-child relationship between a
manufactured item and its components.

List of components for the main item.


Lists the quantity of each component
required to build the main item.
May be multi-level containing other
manufactured items with BOMs

15

Bill of Material

Position lists the components


Defines Quantity required
Zoom in and zoom out capability from Specific Menu

16

Bill of Material
Single Level
Applicable
until
Expiry Date
Bike

Pos.10/Seq.1
Purch. item

Frame (1)

Wheel (2)
A
B (2)

17

Pos.20/Seq.1
Pos.20/Seq.2

Bills Of Material
multi-level

Final Assembly
Sub Assembly

Sub Assembly

Components

Components

Level 0 - Finished Product (Manufactured Only)


Level 1 - Sub Assemblies (Manufactured or Purchased)
Level 2 - Components (Purchased Only)
18

Loops in Production BOMs

CHAIR.XX

SEAT.XX
SEAT
QTY 1

FAB.0004
FABRIC
QTY 0.5

FAB.0001
FOAM
QTY 1

RAW.OOO2
STEEL TUBE
QTY 2.0

FIX.OOO1
ADHESIVE
QTY 0.1

FAB.0004
FABRIC
QTY 0.8

19

PURCHASED
FRAME.XX
FRAME
QTY 2

BACK.XX
BACK
QTY 1

FIX.OOO3
BOLTS

FAB.0001
FOAM
QTY 1

RAW.OOO2
STEEL TUBE
QTY 3.0

FIX.OOO1
ADHESIVE
QTY 0.2

RAW.OOO2
STEEL TUBE

Routings
Start

Routings:

Define the work centers


Work Centers
(tirou0101m000)

Determine how to build the main item


Define the required operations
required to build the main item.

Define any machines used


Machines
(tirou0102m000)

Define which work centers and which


machines are involved with the
manufacturing of the end item.

Define the various tasks


Tasks
(tirou0103m000)

Indicate the time required to complete


each operation.

Define the routing codes per item


Items - Routings
(tirou1101m000)
Define the operations per routing
Routing Operations
(tirou1102m000)

20

End

Routing
Components of an Operation

Work
Centers

Machines
n

Tasks

m
Operation

21

Routing Setup

Work Centers
Machine
Tasks
Basic Components
Routing code
Routing per routing code
22

Routing
Operations
Routing Frame
Sawing

Welding

0.5 hrs

0.3 hrs
Routing Bike
Assembling
1.0 hrs

23

Routing
Types

Default routing

Up to quantity

drilling

assembly

drilling

Line 1
Line 2

Qty. dep. Rou.


24

9999999

Up to quantity
100000
9999999

Routing
Types

Standard
routing

drilling
assembly

Item
specific
routing

painting

25

= item A

= item B

drilling
assembly
painting

= item C

= item D

Routing Operations

Operation Number
Step size
Operation
10

Operation
20
Operation
50
Operation
30

26

Operation
40

Operation
60

Routing Operations

Routing Code and Item create a unique combination of


operations.

27

Calendars and Periods

Calendar Hierarchy
Calendars are selected for use based on a prescribed hierarchy.
For the Work Center the order of searching for a valid calendar is:
Calendar attached to the Department that equals the Work Center
Calendar attached to the Enterprise Unit of the of Department
Company Calendar (from the Companies session
tcemm1170m000)

28

Calendar Flow
Start
Define the availability types.
Availability Types
(tcccp0101m000)
Define Working Hour types
Working Hour Types
(tcccp0103m000)
Define the availability types for the
Standard Calendar for each day of
the week.
Standard Calendar
(tcccp00140m000)
Define Calendar Codes for new
calendar
Calendar Codes
(tcccp0110m000)
Link Availability Types to calendar
Calendar Availability Types
(tcccp0150m000)
Update Calendar to effect changes
Update Calendar
(tcccp0226m000)

Link Calendar to resource

29

Stop

Define Calendar exceptions


Calendar Working Hours
(tcccp0120m000)

Review Questions and Answers

30

Guided Task: <title>

Step 1.
Step 2.
Etc.

31

Lesson 2 Item Control

Manufacturing and Shop Floor Control


ERP LN

Objectives

After completing this lesson you will be able to:


Identify Master Data and Parameters for Unit Effectivity
Define effectivity Units
Identify Item Effectivity Requirements
Define Mask Data
Create Serialized and Lot Control Items

33

Unit Effectivity
Start
Define the parameters for Unit
Effectivity.
Unit Effectivity Parameters
(tcuef0500m000)
Create items for Unit Effectivity
Items - General
(tcibd0501m000)
Create Effectivity Series
Items - Effectivity Series
(tcuef0101m000)
Define the Effectivity Units
Effectivity Units
(tcuef0502m000)
Define the various requirements
Requirements
(tcuef0106m000)
Define any exceptions to the
requirements
Exceptions
(tcuef0105m000)
Apply Unit Effectivity to
Production, Sales, or Planning

34

Stop

Unit Effectivity

What does Unit Effectivity offer ?


Model & Use modifications and variations in E-BOM,
P-BOM, ROU, Sourcing Strategies, Item Purchase
Data. (a Lean Configurator of the production process)
Pegging all Materials to Sales Orders

36

Unit Effectivity Concepts

Effectivity Unit (number)


An ID for a specific model / variation of an end Item (used for configuring
the product structure)
A peg to a sales order line (used for tracking and tracing of materials)

Exception
Linked to an object (= record in BOM, ROU, Sourcing Strategy, etc table)
Defines if BOM-line, etc. is valid or not for a specific EU
Is used to customize processes like BOM-explosion, Selection of Sourcing
Strategy
(explode BOM of item B for Effectivity Unit 10)

37

Bill of Material (1)

A
B
Standard production of item A
(without effectivity unit)
Specific production of item A
(for effectivity unit xxx)
Specific production of item A
(for effectivity unit yyy)

38

C1

Unit Effective
BOM lines

C2
: use components B and C1
: use components B and C2
: use components B, C1 and C2

Routing and Operations (2)

Routing 001:
operation 10 (assembly)
operation 20 (finishing)
operation 30 (paint red)

A
B

C1

Standard production of A
(without effectivity unit)
Specific production of A
(for effectivity unit xxx)

C2
: use operations 10 & 20
: use operations 10, 20 and 30

The routing (instead of the individual operations)


can be unit effective
39

41

Masks
Start
Define the masks that will be used
Masks
(tcibd4102m000)
Define the segments that will make
the mask code
Mask Segments
(tcibd4503m000)

Use Translation
Tables?

Yes

Define the Translation Tables


Translation Tables
(tcibd4504m000)

No

Define the Translation Table


Values
Values by Translation Table
(tcibd4106m000)

Stop

42

Serialized items concept

Serialized items replace lot by unit of SSA Baan IV


(or SSA SSA ERP 5.0c)
A serialized item is a physical occurrence of a standard
item that is given a unique lifetime serial number
Enables you to track the individual item throughout its
lifetime
.for example, through the design, production, testing,
installation, and maintenance phases

43

Serialized items parameters

45

Register Serials during As built (1)


If value is Yes, the registration of the serial numbers used in
production is carried out only in the Serial End Item - As-Built
Components session it is regarded as part of the manufacturing
process.
If the value of this field is No, the serial numbers are recorded the
moment the components are issued from the warehouse.

46

Lesson 3 Cost Price Data

Manufacturing and Shop Floor Control


ERP LN

Cost Price Calculation

Lesson Objectives
After completing this lesson, you will be able to:

Set up cost prices.

View cost price parameters.

Define cost components.

Create operation rate codes.

Define price calculation codes.

Define cost price calculation data.

Define an operation rate.

Add an item surcharge.

Define subcontracting rates.

Define item surcharges for an item.

Simulate a purchase price for an item.

Calculate the cost and the valuation price for an item.

48

Cost Breakdown to Produce Item

Labor = $50
Material = $60

(based on

(based on

Bill of Material

Bill of Material

and Routing

and item data

Overhead = $10
(based on

Total Item Cost = $120

Item data, Routing


and Bill of Material

49

Entering Required Information


Maintain Cost Price
Components

Maintain Cost Price


Ccalculation Codes

Maintain Operation
Rate Codes

Maintain CPR
Parameters
Operation Costs
Material Costs

Purchased Item
Maintain Simulated
Purchase Prices

Maintain Operation
Rates

Manufactured Item

Maintain BOM

Maintain Work Centers

OR

Maintain Task

Parameter Dependent
Maintain Cost Price
Calculation Codes

Maintain Item Data


Maintain Surcharges
by Item

Maintain Surcharges
by Item

OR

OR

Maintain Surcharges
by Item Group

Maintain Surcharges
by Item Group
Maintain
Subcontracting Rates
If operation is
subcontracted

Maintain Routing

50

Calculate Cost Prices

Cost Price Master Data


Start
Define Cost Price Parameters
Cost Price Calculation
Parameters
(ticpr0100m000)
Define Cost Componets used to
capture costs
Cost Components
(tcmcs0148m000)

Use Chart
Details

Set up Cost Component charts


Yes

No

Define Operation Rate Codes


Operation Rate Codes
(ticpr0150m000)
Define Price Calculation Codes
Price Calculation Codes
(ticpr1100m000)

51

End

Cost Component Charts


(ticpr0109m000)

CPR Parameters

Define the Standard Price


Calculation Code.

52

Determine if Fixed Costs


are applied.

Cost Price Terms


Cost Components: Used to categorize production costs
into specific groups called cost types.
Operation rate codes: Used to categorize labor, machine,
overhead, and subcontracting costs associated with the
production of an item.
Price calculation codes: Used to define how a cost or
sales price is calculated. One is used for costing
purposed and all others are simulation codes.

53

Price Calculation Codes

Determines the priority of the purchase price


calculation for purchased items.

54

Price Calculation Codes

Si (Simulated Purch. Pr.): A price calculation


code can be created and used to simulate a
purchase price. These prices are for a unique item
and cost price calculation code in the Simulated
Purchase Prices (ticpr1570m000) session.
Cp (Current Purch. Price): The current
purchase price is manually entered in the Item
Purchase Data (tdipu0101s000) session.
Ap (Average Purch. Price): The average
purchase price is automatically calculated by the
system based on all previous purchase receipts,
when the receipts are matched and approved in the
Finance Package.

55

Lp (Latest Purch. Price): The latest purchase


price is calculated based on the most recent
purchase receipt, after the receipts are matched
and approved in the Finance package.

Cost Price Calculation

Start
Calculate the standard cost for an
item
Caclulate Cost and Valuation
Prices
(ticpr2210m000)
Updte the standard cost price
Actualize Cost and Valuation
Prices
(ticpr2220m000)
Print multilevel cost prices
Print Multilevel Cost and Valuation
Prices
(ticpr2420m000)
End

56

Cost Price vs Valuation Price

Cost Price

Valuation Price

By price calculation code

Five valuation methods

Based on the structure information

Based on actual purchase or production cost

Situation independent: by logistic company

Situation dependent: inventory value, issue,


receipt, transfer

Simulation/Analysis purposes
Inventory valuation & financial accounting

57

Valuation methods

Last in First out (LIFO)


First in First out (FIFO)
Moving average unit cost (MAUC)
Lot costing

Fixed transfer price (FTP)

58

Actual
valuation
methods

Estimated
inventory value
Baan 4

Lesson 4- Shop Floor Control

Manufacturing and Shop Floor Control


ERP LN

Objectives

Lesson Objectives
After completing this lesson, you will be able to:
Define Default Production Order Data
Define Production Order date
Create Production Orders
Issue Production Order Materials
Process Production Orders
Understand Production Order Costing
Create and Process Unit Effective Orders
Process Subcontract Production orders

61

Production Order Status

The status of the production order determines


the actions that can be performed on the
production order. The available production
order statuss are:
Planned
Documents Printed
Released
Active
To Be Completed
Completed
Closed
Archived

62

Shop Floor Control


Order Grouping

Activities by Order Group:


SFC

Warehousing

Print Production Order Documents

Process Outbound Advice

Release Production Orders

Generate Outbound Advice

Report Orders Completed Globally

Release Outbound Advice

Backflush Materials and Hours

Generate Picking List

Cancel Production Orders

Print Inventory by Production Order

Enterprise Planning

Print Shortages by Production Order

Confirm planned production orders

Utilization Reports

transfer planned production orders

Update Physical Location

Report Operations Complete Globally

63

Several Reporting Sessions

Basic Production Order Flow


Start
Create a production order with
subcontract operation included
Production Orders
(tisfc0501m000)
Release Production Orders
Release Production Orders
(tisfc0204m000)
Issue production order component
materials
Material to Issue for
Production Orders
(ticst1501m000)
Report operations completed for
Production Orders
Report Operations Completed
(tisfc0130m000)
Report Production Orders
completed
Report Orders Completed
(tisfc0502m000)
Stop

64

Basic Process for


Production Orders

Production Orders

Can enter orders manually, or view orders that have


been transferred to Shop Floor Control

65

Release Production Orders

When you release a production order, the system


performs the following actions:
Warehousing orders are created in Warehouse
Management. Through these warehousing orders, the
issue of materials and receipt into inventory of end
products are handled.
Allocations of materials are moved to the shop floor
warehouse.
Inspection orders are created in Quality
Management if applicable.
Production orders can be released by using the
Release Production Orders tisfc0204m000)
session.

66

Material Issue for Production Orders

The Direct Process Warehouse Order Line check box in the Items
Production (tiipd0101m000) session determines whether the warehouse
procedure is bypassed when you issue materials. If the warehouse procedure
is bypassed, the materials are shipped directly. If the warehouse procedure is
not bypassed, the quantity to issue is added to the To Issue by Warehousing
field in the Estimated vs. Actual Material Costs (ticst0501m000) session. You
must carry out the rest of the warehouse procedure manually.

The Backflush Materials check box in the Items Production


(tiipd0101m000) session determines whether the material is issued using
backflushing.

The Floor Stock check box in the Items Warehousing


(whwmd4500m000) session determines whether the material is floor stock and
kept on the shop floor as a point of use item.

The manual issuing check box in the Shop Floor Control Parameters
(tisfc0100s000) session determines whether materials are issued with a
manual action.

67

Estimated Materials

Before a production order is released the Estimated Materials (ticst0101m000)


session can be used to view the quantities that are estimated to complete the
production order.
Use this session to list the estimated quantities of the materials used in a
production order and to view or maintain the materials needed to carry out a
production order.

68

Issuing Materials

You can only change the quantity if the


production order has one of the following
statuses:

69

Released

Active

To be Completed

Completed

Backflushing

70

Backflushing

71

Backflushing

72

Subcontract Production Orders

Subcontracting is the use of outside business partners to


complete specific operations or services for your production
process that you may not be able to cover from a capacity
standpoint or are not capable of executing in house.
Two types of subcontracting can be performed.

Unplanned subcontracting: Operations of a production


order are subcontracted in the Subcontract Operations session.
The subcontracting costs are part of the estimated and/or actual
production order costs.

Planned subcontracting: Work centers of the Subcontract


Work Center type are attached to the item routing and include a
Subcontracting Rate and task. The expected subcontracting
costs are part of the standard cost price.

73

Subcontracting Order Flow


Continue

Start
Define subcontracting item
General Item Data
(tcibd0501m000)

Create a production order with


subcontract operation included

Define business partner for


subcontracting

Production Orders
(tisfc0501m000)

Business Partners
(tccom4500m000)

Release Production Orders


Release Production Orders
(tisfc0204m000)

Define a Subcontract Work Center


Work Centers
(tirou0501m000)

Subcontracting
Opeations

Create a subcontracting task

Generate Purchase Order for


Subcontracting item
YES

Tasks
(tirou0103m000)
NO

Link subcontracting business


partner and task to a rate

Report operations completed for


Production Orders

Subcontracting Rates
(ticpr1160m000)

Report Operations Completed


(tisfc0130m000)

Link subcontracting task to item


routing

Report Production Orders


completed

Routing Operations
(tirou1102m000)

Report Orders Completed


(tisfc0502m000)

74

Continued

Stop

Generate Subcontracting
Purchase Orders
(tisfc2250m000)
Approve Purchase Order for
Subcontracting item
Purchase Orders
(tdpur4500m000)
Receive the completed
subcontracting goods
Warhouse Receipts
(twhinh3512m000)

Backflushing

75

Shop efficiency
Order Grouping

Layer on production orders (SFC), which groups


production orders based on characteristics
Execute business procedures by Order Group
Reduction in process time for operations/orders reporting complete

SFC Orders

SFC: 1

Grouped SFC Orders

SFC: 4 SFC: 6 SFC: 12

Group ID: 123

SFC: 1 SFC: 5 SFC: 12


SFC: 2 SFC: 5

Group ID: 125


SFC: 4

SFC: 8

SFC: 8

Group ID: 126

SFC: 2 SFC: 6

76

Shop Floor Control


Order Grouping

Activities by Order Group:


SFC

Warehousing

Print Production Order Documents

Process Outbound Advice

Release Production Orders

Generate Outbound Advice

Report Orders Completed Globally

Release Outbound Advice

Backflush Materials and Hours

Generate Picking List

Cancel Production Orders

Print Inventory by Production Order

Enterprise Planning

Print Shortages by Production Order

Confirm planned production orders

Utilization Reports

transfer planned production orders

Update Physical Location

Report Operations Complete Globally

77

Several Reporting Sessions

Shop Floor Control


Order Grouping

Create EP order group


Grouped planned orders
Confirm/ transfer per order group

Create SFC order group

Grouped SFC orders

Execute activities
by order group
(related to SFC
procedure)

Warehouse
Outbound
and Picking

78

Education
to Move
Forward, Faster

79

sample bullet slide

Sample subhead
First level bullet, 24 pt Arial roman sample text continues
here and on
First level bullet, 24 pt Arial roman sample text continues
here and on
Second level bullet, 20 pt Arial roman sample text continues here
and on
Second level bullet, 20 pt Arial roman sample text continues here
and on

First level bullet, 24 pt Arial roman sample text continues


here and on

80

Instructor Demonstration: <title>

Step 1.
Step 2.
Etc.

81

Production Orders
Definition, Planning and Release of Production Orders
Production Order Materials and Back flushing
Subcontracting of Production Order (Operations)
Production Order Costing (Materials, Operations): Actual vs.
Planned
New:
Buy/Make settings (Date Eff. Item Type)
Shared work centers
Input/output control
Order grouping
Micro routing

82

sample organization chart

Jane Doe
Jane Doe
Jane Doe

83

Jane Doe

Jane Doe

Jane Doe

Jane Doe

Jane Doe

Jane Doe

sample text and single quote

Section introduction
First bullet level, initial line cap,
20 points, Arial
First bullet level, initial line cap,
20 points, Arial
Section introduction

Attribution style

First bullet level, initial line cap,


20 points, Arial
First bullet level, initial line cap,
20 points, Arial

84

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