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
Prerequisites
Education Levels
Advanced,
Productspecific
Knowledge
Advanced
Product
Workshops
General
ERPLN
Knowledge
Course Methodology
Lecture and
Discussion
45%
Business
Concepts
Application
of Concepts
Demonstrations
Hands-on
Practice
50%
Practical Exercises
Measure
Results
5%
Review Questions
Objectives
Item Structures
Item data
Bill of Material
Routing
Cost Price Calculation
10
General Data
Item or Product family
Planning horizon
Time fence
Forecast time fence
Planning Horizon
Order Horizon
Master plan
11
Item Dashboard
12
WC1
13
Flexible
selection
for
production
order planning
Planning
work centers
WC3
WC2
Item structures
Item Production Data
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.
15
Bill of Material
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
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:
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
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
27
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)
29
Stop
30
Step 1.
Step 2.
Etc.
31
Objectives
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
36
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
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 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
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
No
Stop
42
43
45
46
Lesson Objectives
After completing this lesson, you will be able to:
48
Labor = $50
Material = $60
(based on
(based on
Bill of Material
Bill of Material
and Routing
Overhead = $10
(based on
49
Maintain Operation
Rate Codes
Maintain CPR
Parameters
Operation Costs
Material Costs
Purchased Item
Maintain Simulated
Purchase Prices
Maintain Operation
Rates
Manufactured Item
Maintain BOM
OR
Maintain Task
Parameter Dependent
Maintain Cost Price
Calculation Codes
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
Use Chart
Details
No
51
End
CPR Parameters
52
53
54
55
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
Valuation Price
Simulation/Analysis purposes
Inventory valuation & financial accounting
57
Valuation methods
58
Actual
valuation
methods
Estimated
inventory value
Baan 4
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
62
Warehousing
Enterprise Planning
Utilization Reports
63
64
Production Orders
65
66
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 manual issuing check box in the Shop Floor Control Parameters
(tisfc0100s000) session determines whether materials are issued with a
manual action.
67
Estimated Materials
68
Issuing Materials
69
Released
Active
To be Completed
Completed
Backflushing
70
Backflushing
71
Backflushing
72
73
Start
Define subcontracting item
General Item Data
(tcibd0501m000)
Production Orders
(tisfc0501m000)
Business Partners
(tccom4500m000)
Subcontracting
Opeations
Tasks
(tirou0103m000)
NO
Subcontracting Rates
(ticpr1160m000)
Routing Operations
(tirou1102m000)
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
SFC Orders
SFC: 1
SFC: 8
SFC: 8
SFC: 2 SFC: 6
76
Warehousing
Enterprise Planning
Utilization Reports
77
Execute activities
by order group
(related to SFC
procedure)
Warehouse
Outbound
and Picking
78
Education
to Move
Forward, Faster
79
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
80
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
Jane Doe
Jane Doe
Jane Doe
83
Jane Doe
Jane Doe
Jane Doe
Jane Doe
Jane Doe
Jane Doe
Section introduction
First bullet level, initial line cap,
20 points, Arial
First bullet level, initial line cap,
20 points, Arial
Section introduction
Attribution style
84