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PDM Agenda

• Manufacturing Overview

• Product Data Management Overview

• Inventory Overview

• Bill of Material

• Work Center & Routing

• Leadtime

• Engineering Change Management

Manufacturing Overview

2

Manufacturing Overview

Manufacturing

Overview

Customer order

Design BOM and Routing and Product

Costing

Material/Capacity Planning

Manufacturing Accounting

Customer Company

Shop Floor Sales Order

3

Manufacturing Module Integration

ProcurementPurchase orders

Supplier information

Supplier performance

Supplier/item

relationships

Approval

Receiving

Authorization

Inventory Management :Items, Branch/plant, Stocking locations, Costs, Prices, Characteristics, Lot & serial information

Inv

en

tor

y T

ran

sa

cti

on

sR

ec

eiv

ing

, Is

su

es

, Tra

ns

fer

s,

Ad

jus

tme

nts

Accounts Payable

Voucher paymentsReports

Sales Order ProcessingSales orders, Shipment,

Returns, Special

Instructions, Customer

information, Pricing

Plant

MaintenanceParts Lists,

Work Order

Costs

Issues, Returns

General Ledger : Inventory movement, Variances, Sales, Returns, Breakage, Taxes

Payroll / HREmployee

Data

Payroll

Information

Accounts

ReceivableInvoices/Cash

receipts

Credit/Collection

Mgmt

StatementsManufacturing

Planning Systems

Resource Planning

Forecasting

Engineering Change

Work Orders

Work in process

Shop Floor Control

4

3

Integration with Other System

Product Data

Management

MPS

MRP

DRP

Shop Floor

Control

Inventory

Management

Manufac.Accounting

Product Costing

Manufacturing Systems

Inventory Management

Product Data Management

Bills of Material

Work Centers

Routing

Product Costs

Item Master

Item Branch/Plant

Item Costs

Sales Order

History

Best Fit

Detail Forecasts

G41G30

Forecasting

G34

4

Manufacturing Systems

Material

Requirements

PlanningWork Order Processing

Material Issues

Hours and Quantities

Completions

Journal Entries

Variances

Shop Floor

Control

G34G31

G34

Master

Production

Scheduling

Demand from

Sales Order or

Forecast

Time Series

Supply / Demand

Dependent demand

Material Plan

Validation

System Concepts

Inventory

System

F4101

Item Master

F4102

Item Branch/Plant

Product Data

ManagementF3002

Bill of Material

F3003 Routing

Engineering Change Order

Product Costing

5

System Concepts

Product Data

Management F3002

Bill of Material

F3003 Routing

Engineering Change Order

Product Costing

Shop Floor

Control

F3111

Part List F4801

F3112 Work Order

Routing

Manufacturing Accounting

Product Data Management

Overview

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Manufacturing Flow

Product Data Management

Product Costing

Material/Capacity Planning

Manufacturing Accounting

Your company

Shop Floor

Product Data Management Features

All the types of Manufacturing

�Discrete

�Process

�Repetitive

Use BOM, Work Centers and Routing

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Discrete Manufacturing

Work Order driven by item

� Parts List

� Routing Instructions

� Specific Order

� Date

� Quantity

� Production of distinct items

Process Manufacturing

Production results

include

the completions of one or

more co/by products

Work Order is driven by the

process, resulting in...

Ingredients List

Routing Instructions

Co- and By- Products

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Repetitive Manufacturing

Schedule driven by product

families with...

� Similar End Items

� Smooth, continuous demand

� Product families assembled

on a dedicated flow line

� Reduced setup and leadtimes

� Rate Schedules

� High volumes

� Low Work In Process

Production driven by customer demand

Sales Order driven

Supports use of sub-assemblies

Assemble-to-Order Manufacturing

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Inventory Overview

How are Units of Measure Used?

produced in a unit of measure

other than primary

consumed in a unit of measure other than primary

Production

Component

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19

20

11

21

22

12

13

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Product Data Management

Product Data Management

� Bills of Materials

� Work Center & Routing

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15

Bills of MaterialBills of Material

Rim (P)

Bicycle

Wheel Assy. (M)

Lock (P)Chain Assy.

(M)Brake

(P)Frame

(M)

Bearing (P)

Seat (P)

Chain (P)

Pedal (P)

Handle Bar (P)

Tube/Pipe (P)

Plate (P)

Tyre (P)

Bill of Material is the method of defining and communicating

the structure of the product.

Define:

� Parent/Component relation

� When an item is consumed in manufacturing

� When an item is issued in manufacturing

� Quantity

� Branch/Plant

Define Bill of Material

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Bill of Material CharacteristicsBill of Material Characteristics

� Supports Product Costing� Allows Master Schedule to be stated in

the highest possible end items

� Reflects material flow -how product is built

Variable Bill of MaterialVariable Bill of Material

� Supports Discrete and Process environments

� Specifies component requirements

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Based on % of sales

Module Family

Module Family

D Hcolor

D Hcolor

D Hcolor

Module FamilyMountain Bike

SubsetModule Group

DH

SubsetModule GroupActive

SubsetModule GroupCarbon

Planning BillModular Bill of MaterialPlanning BillModular Bill of Material

Percent Bills of MaterialPercent Bills of Material

� Supports Discrete and

Process environments

� Used in highly

regulated industries

� Enforces specified

quantities for an

ingredient or

component

Fixed/Variable field = %

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Batch Bills of MaterialBatch Bills of Material

Supports Discrete and Process environments

� Used in conjunction with shop floor constraints

� Quantity of a parent item

� Specifies component requirements

Bills of Material

Parent Item

A

Raw Material

CPart

BSub Assembly

D

Raw Material

ESub Assembly

GPart

F

PartB

Raw MaterialE

Single-Level

Indented-Level 4

3

Parent

Component

0

1

2

Parent

Component

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Bill of Material Item Cost

Shop Floor Control

MPS/MRP

Product Costing

Parent Item

A

Raw Material

C

Part

B

Sub Assembly

D DemandSupply

Information Flow

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Work Center & RoutingWork Center & Routing

Work Centers

� People and machines that make up the production

facilities on the shop floor where the routing operations

occur

� Consists of one or more

� People

� Machines

� Considered as one unit for

� Capacity Planning

� Detailed Scheduling

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Define Work Centers

Receipt Inspection 100-101

Cutting Machine 100 -102

Welding Machine 100 -103

Assembling100-104

Testing100-105

Milling Machine 100 -106

Final Inspection100-107

Painting 100-108

Packing100-109

� Work Center Number and Description

� Define Work Center as a Business Unit

� Define:

� Operator, machine and hours per day

� Rates:

� Setup

� Labor

� Machine

� Overhead

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Routings

� Define:

� Production Process

� Operations

� Sequence

� Applicable Work Centers

� Standards for setup and run times

� Types of Routings

� Manufacturing

� Alternate

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Information Flow

1.2.3.

Process Routing Work Center

Shop Floor Control

CRP

Product Costing

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Scrap, Yield and Shrinkage

Scrap - % ของ Component ที�จะ unusable ระบุใน BOM

Yield - % ของ Output ที�จะได้เมื�อผ่าน Operation นี/ระบุในRouting

Shrink - % ที� Expected Loss of Parent เนื�องจากธรรมชาติเช่นการหดตัว ระบุใน Item Branch(F4102)

Yield in Routing

Operation Yield Compound Yield

40 80 80%

30 90 80 x 90 = 72%

20 100 72 x 100 = 72%

10 95% 72 x 95 = 68%

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Planned Yield Update

Operation Scrap ใน BOM

Operation Compound Yield Operation Scrap

40 80 100/80 - 100 = 25

30 72 100/72 - 100 = 39

20 72100/72 - 100 =

39

10 68 100/68 - 100 = 47

Lead Time ConceptLead Time Concept

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Lead Time Type

� Fixed Lead Time

� Level Lead Time

� Cumulative Lead Time

� Manufacturing Lead Time

� Variable Lead Time

� Lead time per unit

Lead Time Example

A

B C

D E

LLT = 3Cum LT = 3

LLT = 5Cum LT = 5

LLT = 4Cum LT = 9MFG LT = 4

LLT = 2

Cum LT = 2

LLT = 1Cum LT = 10MFG LT = 5

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Engineering Change Management

Engineering Change Management

Engineering Change Order Features

ECO

•Costs•Dates

Additional Details

1. Test2. Approve3. Change

ECO Routings

ECO Approvals

•Engineering •Production

Item Changes

A

1 2 3 4X

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ECO Process

1. Set Up ECO System

2. Create ECO

3. Approve ECO

4. Implement ECO

ECO Change Types

N add new part

C change existing part

S swap old part with new part

R remove existing part