Transcript Document

TT4
Production Orders
7/18/2015
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7/18/2015
Mixer
Snack Bar Line
Mixer
Form
Bake
Pack
Mixer
Production (200)
Mixer
Finished Goods Warehouse (300)
Raw Material Warehouse (100)
Work Centers for Fitter Snacker
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Raw Material Warehouse (100)
Step 1: Detailed Instructions
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Mixer
Mixer
1) Release Order for 500 LB of
## Dough NRG-A
2) Issue goods to production order (oats,
wheat germ, etc.) from SLOC 100
3) Confirm production of 500 LB
(accounting)
4) Receive 500 LB of ## Dough NRG-A
into SLOC 200
Mixer
Production (200)
Mixer
3
1) Release Order for 7 Cases of
## Dough NRG-A
2) Issue goods to production order (500
LB of ## Dough NRG-A)
3) Confirm production of 7 Cases
Snack Bar Line
(accounting)
4) Receive 7 Cases of ## NRG-A into
SLOC 300
Form Bake Pack
Production (200)
7/18/2015
Finished Goods Warehouse (300)
Step 2: Follow the Pattern
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Functions of Production Orders





Status Management: Tracking, User-defined status
Scheduling
Calculation of Capacity Requirements (detailed)
Costing
Availability Checks (material, capacity, PRTproduction resources and tools)
 Printing of Paper Orders/related documents
 Assembly drawings and instructions
 Inspection instructions
 Storage regulations
 Material Staging: withdrawal of materials used in
production, e.g. components and sub-assemblies
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Functions of Production Orders
 Confirmations: quantities, activities, times
 Goods receipt: receipt of completed materials
 Period-end closing: Process cost allocation, overhead
costs, surcharges, WIP calculation, variance
calculation, order settlement
 Archiving and retrieval
 Many more: rework, serial numbers, as-built, quality
control, etc.
 Production Orders capture actual data—
costs, dates, etc.
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Planned Orders vs. Production Orders
 Planned Orders are for PLANNING
 Production Orders are for EXECUTION
Planned Order 3 weeks in future
Planned Orders 2 weeks in future
Planned Orders 1 week in future
Production Orders released today
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Master Data for Production Orders
 Master Data is data that does not change frequently
 Master Data for the production order comes from:
 Material Master
 Bill of Material (BOM)
 Work Center
 Routing
 Production Resources/Tools (PRT)
 Materials like gages, fixtures, test equipment
 Can also be items like drill bits that can be
consumed in production but aren’t consumed
INTO the product
 Most Production Order data comes from BOM and
Routing
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Archiving &
Deletion
Order Request
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Order
settlement
Order Creation
2
Availability
Checks
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Variance
Calculation
Goods Receipt
3
Production
Order
Cycle
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13
WIP
Determination
Machine
Reservation
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Order Release
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12
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Confirmation
Upload from
PDC system
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10
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Download to
PDC system
Order Print
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Material staging
Material withdrawal
posting
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Production Order Cycle
 The Production Order goes through many
activities, many of which can run automatically
or in the background
 Cost Object Controlling activities (WIP
determination, variance calculation, and
settlement) are periodic and usually performed
in the background
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Methods of Creating Production Orders
 Direct (manually)
 From planned order (created by MRP)
 Order by order: an individual planned order
is turned into a production order
 Mass processing: a group of orders is
processed in a batch
 For sales order (can be automatic)
 For rework
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Scheduling
 MRP calculations determine Basic Dates

Basic start date: the earliest possible start of
production

Basic finish date: the latest possible date by which
production has to be finished

The opening period (planned open date to basic
start date) is the time required by the MRP
controller to convert the planned orders into
production orders or purchase requisitions (defined
in scheduling margin key—specified in material
master).
 Basic dates are calculated using in-house production
time (or replenishment lead time for purchased
components) and backward scheduling.
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Basic Dates
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Lead Time Scheduling
Float
before
production
PS
OP
OP
OP
OP
OP
……..
0010 0020 0030
0080 0090
SS
SF
Queue
time
ES
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Setup
time
LS
Processing
time
Teardown
time
EF
Float
after
production
GR
process
time
PF
Pick/pack
time
AD
Wait
time
LD
Load
time
Transit
time
GI
RDD
Move
time
LF
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Lead Time Scheduling
in-house
production time
Float
before
production
PS
PS:
SS:
SF:
PF:
relevant to
sales order
OP
OP
OP
OP
OP
……..
0010 0020 0030
0080 0090
SS
Float
after
production
SF
Planned Start Date (Basic Date)
Scheduled Start Date
Scheduled Finish Date
Planned Finish Date (Basic Date)
Float before production and
Float after production defined in
scheduling margin key (assigned
in7/18/2015
material master)
GR
process
time
PF
Pick/pack
time
AD
LD
Load
time
Transit
time
GI
RDD
AD: Planned Availability Date
LT: Loading Time
GI: Goods Issue Date
RDD: Required Delivery Date
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Lead Time Scheduling
used in capacity planning
Queue
time
ES
ES:
LS:
EF:
LF:
Setup
time
LS
Earliest Start Date
Latest Start Date
Earliest Finish Date
Latest Finish Date
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Processing
time
Teardown
time
EF
Wait
time
Move
time
LF
Detailed operation times can be
used to calculate in-house
production time automatically
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Lead Time Scheduling
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Status Management
 Status Management is one tool that can be used to
manage released production orders
 A status can allow, allow with warning, or block a
business transaction
 Two status types are available
 System status: internal, predefined, fixed number
 User status: freely definable, set by user
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Status Management
Status
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Status detail
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