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04mfg62s-MDM

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04mfg62s-MDM

    2010-4-29 2:58:00

    Insert Tab Here Unit 4Manufacturing Data Management

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    Unit 4Manufacturing Data Management Unit Introduction ........................................................................................................ 1

    Objectives ............................................................................................................. 1

    Terminology .......................................................................................................... 2 Manufacturing Data Management .............................................................................. 3

    MRP II and Manufacturing Data Management Integration ................................... 3

    Manufacturing Data Management Integration ...................................................... 4

    Manufacturing Data Management Setup Process ................................................ 5

    Bills of Material .......................................................................................................... 6

    Bills of Material Integration ................................................................................... 7

    Bills of Material Uses ............................................................................................ 8

    Parent and Component Relationship ................................................................... 9

    Parent ............................................................................................................. 9

    Component ...................................................................................................... 9

    Bill of Material Levels ......................................................................................... 10

    Single Level Bill of Material........................................................................... 10

    Multi-Level Bill of Material ............................................................................. 10

    Bill of Material Tree Structure ............................................................................. 11

    Manufacturing Data Maintenance ...................................................................... 12

    Phantom Items.................................................................................................... 14

    Single Unit versus Batch Bills of Material ........................................................... 15

    Single Unit Bill of Material ............................................................................. 16

    Batch Bill of Material ..................................................................................... 17

    Global versus Facility-Specific Bills of Material.................................................. 18

    Primary versus Alternate Bills of Material........................................................... 19

    Planning Bills ........................................................................................................... 20

    Planning Bill Components .................................................................................. 21

    Features and Options ......................................................................................... 22

    Kits ..................................................................................................................... 23

     Table of Contents 4-i

    Assortments ........................................................................................................ 24

    Planning Bills Comparison .................................................................................. 25 Process Design ........................................................................................................ 26

    Departments ....................................................................................................... 27

    Work Centers ...................................................................................................... 28

    Work Center Loading Codes ......................................................................... 30

    Run Hours versus Machine Hours................................................................. 31

    Machines ............................................................................................................ 32

    Routings and Operations .................................................................................... 34

    Operation Time .............................................................................................. 36

    Basis Codes .................................................................................................. 38

    Global versus Facility-specific Routings ............................................................. 39

    Primary versus Alternate Routings ..................................................................... 40

    Work Center and Routing Implementation Tips .................................................. 42

    Manufacturing Data Management Inquiry ................................................................ 43

    Formulation Assistant............................................................................................... 44

    MDM Review ............................................................................................................ 48

    4-ii Manufacturing WorkshopStudent Guide

List of Figures

    Figure 4 - 1. MRP II Process Highlighting Manufacturing Data Management .......... 3

    Figure 4 - 2. Manufacturing Data Management Integration ...................................... 4 Figure 4 - 3. Manufacturing Data Management Setup Process ................................ 5 Figure 4 - 4. Bills of Material Integration ................................................................... 7 Figure 4 - 5. Bills of Material Uses............................................................................ 8 Figure 4 - 6. Bill of Material Single Level ................................................................ 10 Figure 4 - 7. Bill of Material Multi-Level .................................................................. 10 Figure 4 - 8. Bills of Material Tree Structure ........................................................... 11 Figure 4 - 9. Manufacturing Data Maintenance ...................................................... 12 Figure 4 - 10. Single Unit Bill of Material ................................................................ 16 Figure 4 - 11. Batch Bill of Material ........................................................................ 17 Figure 4 - 12. Production Planning/Forecasting Bill of Material ............................. 20 Figure 4 - 13. Features and Options Bill of Material ............................................... 22 Figure 4 - 14. Kit Bill of Material ............................................................................. 23 Figure 4 - 15. Assortment Bill of Material ............................................................... 24 Figure 4 - 16. Departments and Work Centers ....................................................... 26 Figure 4 - 17. Department Master Maintenance ..................................................... 27 Figure 4 - 18. Work Center Master Maintenance ................................................... 29 Figure 4 - 19. Machine Maintenance ...................................................................... 32 Figure 4 - 20. Machine Speed Factor Example ...................................................... 33 Figure 4 - 21. Routings and Operations ................................................................. 34 Figure 4 - 22. Routing Maintenance ....................................................................... 35 Figure 4 - 23. Operation Time ................................................................................ 36 Figure 4 - 24. Alternate Routing Method ................................................................ 41 Figure 4 - 25. Where Used Bill of Material ............................................................. 43 Figure 4 - 26. Formulation Assistant ....................................................................... 44

     Table of Contents 4-iii

List of Tables

    Table 4 - 1. Effective and Discontinue Dates .......................................................... 13 Table 4 - 2. Planning Bill Components .................................................................... 21 Table 4 - 3. Planning Bill Type Comparison............................................................ 25 Table 4 - 4 Work Center Loading Codes ................................................................ 30 Table 4 - 5. Run Hours versus Machine Hours ....................................................... 31 Table 4 - 6. Interoperation/Operation Time ............................................................. 37 Table 4 - 7. Global versus Facility Specific Routings.............................................. 39

4-iv Manufacturing WorkshopStudent Guide

Unit Introduction

    In this unit we will set up the foundation pieces needed for manufacturing. We will cover bills of material, planning bills, process design, and reports. These are grouped under Manufacturing Data Management (MDM).

    Objectives

    At the end of this unit you will be able to:

    ? Identify and set up parent, component, and where-used relationships in bill of material

    structures.

    ? Identify and set up departments, work centers, and routings. ? Define planning bill types.

     Manufacturing Data Management 4-1

    Terminology

    Planning bill using options. Assortments

    Listing of all subassemblies, components, and raw materials Bills of Material (BOM)

    that go into a parent item, and the required quantity of each.

    Item used to manufacture another item. Component

    Planning bill using features (characteristics) and options Features and Options

    (extras).

    Total independent and dependent demand for a part or Gross Requirements

    assembly within a time period.

    Planning bill using standard components. Kits

    Amount of time needed to produce an item. Lead Time

    System allowing production control, engineering, and cost Manufacturing Data

    accounting to retrieve and use product structure, routing, Management (MDM)

    and work center information for a variety of planning and

    costing needs.

    Specific task or set of tasks within a routing. Operations

    Item made up of one or more component items. Parent

    Term used to describe transient or non-stocked items. Phantom Item

    System suggested replenishment orders not yet accepted by Planned Order

    the planner.

    Artificial groupings of items used for planning or specialty Planning Bills of Material

    purposes.

    Determining what material is needed and when. Priority Planning

    Calculated inventory amount at end of time period. Projected On-hand

    Traditional method for restocking consistent demand. Reorder Point

    Process of establishing, measuring, and adjusting limits or Resource Planning

    levels of long-range capacity.

    Set of information describing an items manufacturing Routings

    method and sequence.

    Manufacturing orders, purchase orders, or firm planned Scheduled Receipts

    orders with an open balance due in a particular time period.

    Calendar used in inventory and production planning, Shop Calendar

    allowing scheduling to be done based on actual

    manufacturing time available.

    4-2 Manufacturing WorkshopStudent Guide

Manufacturing Data Management

    Manufacturing Data Management defines both product design and process design.

    ? Product design includes both bills of material and planning bills of material

    ? Process design encompasses departments, work centers, machines, and routings

    MRP II and Manufacturing Data Management

    Integration

    The following Manufacturing Resource Planning (MRP II) figure highlights Manufacturing

    Data Management (MDM) components. These pieces are illustrated as part of the MRP II

    Foundation. Manufacturing functions cannot be performed without having these set up in the

    system.

    Business Planning

    AccountsSales PlanningOrderReceivablePlanningForecastingProcessingItemBillsMaster

    Production PlanningBill ofIResourcesN

    GeneralVRough CutMasterLedgerBills ofCapacityProductionEMaterialPlanningSchedulingN(Configurable)DepartmentsTMaterialCapacityWorkRequirementsRequirementsOCentersPlanningPlanningRRoutingsYFinite ForwardSchedulingAccountsCostPayableStandardsActualsCostProductionAccountingActivityPurchasingControl

    PerformanceMeasurement

    Figure 4 - 1 MRP II Process Highlighting Manufacturing Data Management

     Manufacturing Data Management 4-3

Manufacturing Data Management Integration

    The figure illustrates Manufacturing Data Management (MDM) integration with other BPCS

    products. Inventory (INV) feeds information into Manufacturing Data Management. All

    other products shown here receive information from Manufacturing Data Management.

    Detail Capacity

    Planning

    Rough CutCAPFinite ForwardCapacity SchedulingPlanningFFSCAP

    Detail Work CenterDetail Work CenterAvailable CapacityDetail Work CenterAvailable CapacityAvailable Capacity

    ManufacturingShop FloorBill of ComponentCritical ResourcesData Control/usage andand RequirementsResourcesJust-In-Timeitem detailsfor MPS ItemsManagementCAPSFC/JITMDM

    Item, Warehouses,Product costingWIP Itemsand MaterialBackflushOutsideBOM and SchedulingProcessingInformation

    CostInventoryAccountingINVMaterialCSTPurchasingRequirementsPlanningPURMRP

    Figure 4 - 2 Manufacturing Data Management Integration

    4-4 Manufacturing WorkshopStudent Guide

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