1

Shop Floor Control Agenda

• Shop Floor Control Overview

• Setup Shop Floor Control

• Shop Floor Control Process

• Enter Work Order

• Commitment

• Work Order Processing

• Issue Material

• Record Hours and Quantity

• Work Order Completion

Shop Floor ControlOverview

2

System Integration

Product Data Management

DRP/MPS/MRP

Procurement

Inventory Management

Payroll

Sales Order Management

RCCP/CRP Manufacturing Accounting

Shop Floor Work Order Flow

Record Hours and Quantities

Create Work Orders� Attach Parts List� Attach Routing Instructions� Generate shop paperwork

Schedule WorkPick/Issue Materials

Commitments - Availability Checking - Capacity

Complete Work Orders� Update Inventory� Backflushing� Post Labor

3

Shop Floor Management

Setting Up

Shop Floor

Management

Performing

Shop Floor

Processes

Accounting

Shop Floor

Processes

Setup Shop Floor Control

4

Define Manufacturing Constants

Manufacturing Constants are branch-specific information

which affects processing throughout the JD Edwards

EnterpriseOne Manufacturing systems.

�Manufacturing Constants

� Shifts

� Commitment Control

� Costing Options

7

5

Define Shop Floor Calendar

Define

� Working Day

�Weekend

�Holiday

6

Define Employee Labor Rate

Employee Labor Rate is used to define employee

labor rates that the system uses to calculate labor

costs

�Employee Code/Address Book Number

�Employee Name

�Rate / Hour

7

590

In Process Work Order’s - Run Work Order activity as needed - Partial Completions

9095

Complete adjusting manufacturing entries- Status to ‘95’- Manufacturing complete

9596

Manufacturing Accounting complete- Work Order Activity96

97 Variance Report Printed

9799

Variance Accounting complete- Purge

Step/eventsWork Order Status

Next Number

14

8

Shop Floor Process

Shop Floor Processes Cycle

Enter WO

WO Process

Invent Issue

Report Hrs &

Quantity

WO Completion

9

Work Order Creation� Manually

� Automatically - by acting on messages

� From Sales Order

� Define Item to create a certain quantity by a given date

� Create user-defined codes for type, priority, status

Work Orders

Routing

10 Mix

20 Add Liquids

30 Bake

40 Package

Parts List

Sugar

Whey

Calcium Stearate

Flavors

Soybean Oil

10

Attach Part List

1. Attach Manually

2. Automatic Attach Part List when Attach Routing

(Define in Processing Option)

3. Automatic Attach Part List from Order Processing

Program

What happens when attach Part List and Routing

1. Specified Bill/Routing Type with Specified batch

quantity

2. Specified Bill/Routing Type with Zero batch quantity

3. Bill/Routing Type M with Specified batch quantity

4. Bill/Routing Type M with Zero batch quantity

11

What happens when attach Part List and Routing

� Shrink, scrap, and operational yield.

Parts List

� Generate Pats List

automatically

� Override component

requirements, commitments,

and quantities

� Modify Parts List real-time

� Use substitute items if

necessary

12

Attach Routing

1. Attach Manually

2. Automatic Attach Routing when Attach Part List

(Define in Processing Option)

3. Automatic Attach Routing from Order Processing

Program

13

Routing Instructions

� Generate routings automatically

� Use master routings

� Outside operation

Item No*OP Operation Seq.

� Change work center, operation information

� Change sequence of operation steps

� Modify routings real-time

14

How calculate the start date

� Fixed Leadtime

Request date = 15/10/10

Level leadtime = three days

Start date = 12/10/10

� Variable Leadtime

{(Leadtime per unit x order quantity / TIMB (Item balance)) + setup + queue}/Work hours per day

Request date = 15/10/10

Leadtime per unit = 32 hours/1000 Units

Work order quantity = 1000

Setup = 1 hour Queue = 9 hours

Work Hour Per Day = 24 hours

{(32 x 1000/1000) + 1 + 9} / 24 = 2 day

Start date 13/10/10

Commitments

15

Hard Vs. Soft Commit

� A hard commitment

designates inventory to a

specific inventory location or

lot

� A soft commitment

tentatively commits

inventory to work order,

although not tied to a

location or lot

Where commitments are made . . .

Manufacturing Constants

Backflush Option - Specified location for Work center or use

commitment control

Commitment Control

1. Primary location where work

order originated

2. Branch/Plant boundaries may be

crossed

3. Any location within a

Branch/Plant

16

When hard commitments are made . . .

Manufacturing Constants

Hard/Soft Commit

1. Hard commit at creation of

Parts List

2. Soft commit change to

hard commit during work

order pick list print process

3. Soft commit through

inventory relief

How hard commitments are made . . .

Item Branch/Plant

Commitment Method

1. Primary Location, then

Location with the most

quantity

2. Lot number starting with

lowest

3. Lot expiration date, earliest

first

17

Managing Commitments for Grade and Potency Controlled Items

Not available

low end high end

Can be committed and issued

Not available

Valid Range

18

Managing Commitments for Grade WO require 800 and grade range A01-A03

Back

Commitments for Potent Units

Active ingredient in a product

On Hand Requirement

200 GP

80% (50 GA)(.80) = 40 GP

40% (400 GA)(.40) = 160 GP

19

Managing Commitments for PotencyWO require 500 GP

30 / 70%

= 43 Back

470

Repost Work Order Commitments

� Clear outdated or invalid commitments

� Repost commitments and on-order quantities specified

in a work order to current requirements

� Clear (set to zero) Quantity Commit to Work Order and

Quantity on Work Order

� Repost Value in Quantity on Work Order from F4801 :

Quantity on Order – (Quantity Complete + Quantity Scrap)

� Repost Value in Quantity Commit on Work Order from F3111 :

Quantity require – Quantity issued

20

Shop Floor Processes Cycle

Enter WO

WO Process

Invent Issue

Report Hrs &

Quantity

WO Completion

Process Work Order

� Generate Part List, Routing or both

� Update Status Code of Work Order

� Print Report - Shortage List, Shop Paper Work, Shop Packet

Summary

� Issue Inventory automatic through a batch program

(Preflush)

� Generate Purchase Order automatic for Outside Operation

� Calculate Standard Cost for Configured Item

� Substitute Item performed

21

Shop Floor Processes Cycle

Enter WO

WO Process

Invent Issue

Report Hrs &

Quantity

WO Completion

Pick/Issue

� Relieve inventory using

one of the following:

� Manual issue

� Preflush

� Relieve upon work order

completion using:

� Backflush

� SuperBackflush

22

Pick/Issue

Shop Floor

Update Part List (F3111)

23

Production Scheduling

� Schedule work center production for work orders

� Compare planned against actual schedules

� Use the scheduling workbench to review and change

schedules real-time

Capacity

Orders

24

Shop Floor Processes Cycle

Enter WO

WO Process

Invent Issue

Report Hrs &

Quantity

WO Completion

Hours and Quantities

� Enter and track time and quantities by

� Work Order

� Employee

� Track resource usage by work center

� Compare standard Vs. actual

� Charge actual hours

25

Post Hours and Quantities

� Run Hours and Quantities Update program

� Interactively through Hours and Quantities entry

Operation Hours Quantity

Hour & Quantity

Shop Floor

Update Routing (F3112)

Hour & Quantity

(P311221)

Shop Floor

Write Time Transaction (F31122)Post

26

Review this Report and Run Update Hour by R31422 Update Hour Program

27

Shop Floor Processes Cycle

Enter WO

WO Process

Invent Issue

Report Hrs &

Quantity

WO Completion

Completions to Inventory

� Partial completions as they occur

� Full completion when entire work request is satisfied

Inventory

Item Loctn Qty

Candy Bin-X

2000

Complete2000

28

Complete

Shop Floor

Update Work Order Header (F4801)

Inventory Complete

(P31114)

Process Manufacturing, Quantity Complete recorded in F3111