Use this document as an aid if you run into problems during the actual running of the routines within IBS Manufacturing.
You will find the following information, per routine:
- Controlling parameters, meaning the data that controls how the routine behaves.
- Prerequisites, meaning the mandatory data that must exist in the system’s base tables and files, to be able to work through the tasks, per routine, in the most effective way.
Note: In some cases, only the controlling parameters are given for a routine, and vice versa. This is because not all routines require such data.
Working with work centres
Controlling parameters
- The Work centre type field in the Work centre file defines if the work centre is used as a work centre or a department section in the system.
- The Workl planning type field in the Work centre file defines if run/labour time or machine time is used as a base for the workload calculation.
Prerequisites
- A calendar must be set up in the Calendar ID table.
Working with tools
Controlling parameters
There are no controlling parameters.
Prerequisites
- Items must exist in the Item file.
- Work centres must exist in the Work centre file.
- A bill of material must exist in the Structure file.
- A bill of routing must exist in the Structure file.
- The Calendar manufact field must be defined in the MFG control file. This MFG calendar must also be generated in the system with normal capacity.
Working with item structures
Controlling parameters
- The Variant handling field in the MFG control file controls if variants of item structures can be used or not in structure maintenance. Note: If the Variant handling field is set to NO, then the Variant field is not displayed in structure maintenance.
- The Warehouse field in BOM in the MFG control file controls if a production warehouse can be defined for the structure or not. Note: If the Warehouse in BOM field is set to NO, then the Warehouse is not displayed in structure maintenance. Note: It is only allowed to set the Warehouse in BOM field to YES if the Cost by warehouse field is set to YES in the DIS control file.
Prerequisites
- The end item and the components must exist in the Item file.
- The item for which a structure is created must have item type 1 (end product) or 2 (subassembly).
- Work centres must be set up in the Work centre file.
Working with item lead times
Controlling parameters
- The Workl planning type field in the Work centre file defines if run/labour time or machine time is used in the calculation of the production lead time.
- The values used in the calculation of the production lead time are retrieved from the Normal capacity, Number of shifts, Number of machines, Efficiency factor, Man factor and Resources per job fields in the Work centre file.
- The Availability check field in the Item file defines if a component is critical. The component is critical if the field is set to 1 or 2.
Prerequisites
- Items in the Item file for which lead times should be calculated.
- Operation times must be entered for the items in the bill of routing.
Updating BOM/BOR from manufacturing order history
Controlling parameters
- The Order statistics field in the Manufacturing order type table defines if a manufacturing order is saved in the Manufacturing order history file when it is closed.
Prerequisites
- The Manufacturing order cost control (COST_CONTR) batch job must be run with the Create statistics field set to YES before the BOM/BOR can be updated.
Working with cost models
Controlling parameters
- The Cost model field in the MFG control file defines the cost model to be used in the company.
Prerequisites
There are no prerequisites.
Calculating cost
Controlling parameters
The following parameters control the routine:
- Cost model id must be defined in the MFG control file
- Item w c price type must be defined in the MFG control file.
- Item cost type pc must be defined in the MFG control file.
Prerequisites
- Work centres and hour prices for run labour, machine price etc. must exist in the Work centre file.
- The item must exist in the Item file, with prices for purchased items and standard quantity PC for produced items.
- Overhead tables must be defined according to the used cost model.
- Bill of material and bill of routing have to be defined in the Structure file.
- Material quantity, Machine time, Run and labour time and Set-up time have to be defined in the Structure file.
- The Machine price, the Run and labour price, the Set-up price and the overheads (amount and/or percentage) for the work centre have to be defined in the Work centre file.
Working with MRP
Controlling parameters
The following sections display the controlling parameters for MRP in the application control files, the Item file and the Structure file.
Application control files
- The Forecast period type field in the IC control file is relevant if a supply plan forecast version is selected when the MRP calculation is run. Depending on this value, the netting between forecast and customer orders is performed on a weekly or monthly basis. You indicate in the MRP calculation in which period the netting should start.
Note: The forecast period is retrieved from the IC control file if IBS Inventory control is activated. Otherwise, the period is retrieved from the Sales/SOP period field in the MFG control file.
- The Main whs mtrl alloc field in the MFG control file controls how the material that is included in a manufacturing order should be reserved and in what warehouse depended demand MRP record should be created.
If YES, the material will be reserved in the warehouse that has been entered in the Allocation warehouse field in the bill of material. If this field is blank the reservation will be done in the component’s main warehouse defined in the Item file.
If NO, the material will be reserved in the warehouse from which the requirement of the main item emerged. MRP calculates requirements in those warehouses where the forecasts, customer orders, manual reservations and the manufacturing orders reside.
Item file
- MRP results can be selected according to the planner that is defined in the Planner field in the Item file, Basic data. Note: The planner may also be defined on warehouse level.
- The Requirement calc field in the Item file, Manufacturing information controls if the item requirement should be calculated. This field must be set to YES if MRP is to be run.
- The Number of cons days field in the Item file, Manufacturing information is used for items defined with order rule 3. It controls the number of days to be included in the requirement calculation.
- The Production lead time field in the Item file, Manufacturing information indicates the number of days it takes to manufacture a parent item. This value is used to calculate the start date for order proposals in MRP.
Note: Production lead time may also be defined on warehouse level. Note: Lead time for purchased items is defined in the Lead time field in the Item file, Supplier information.
- The Order rule field in the Item file, Manufacturing information controls how the requirement should be calculated in MRP. The order rule can also be defined on warehouse level. The following order rules exist:
1 Lot for lot: Indicates that one proposal per requirement is created with the same quantity as the requirement. Only those requirements arising the same day are put together. 2 Fixed order quantity: Indicates fixed requirements according to order quantity (EOQ). Only those requirements arising the same day are put together. - If the requirement (theoretical on hand) is less than EOQ, a proposal is created for the EOQ.
- If the requirement (theoretical on hand) is greater than EOQ, a proposal is created for the required quantity.
- If a value is entered in the Multiple quantity field in the Item file, a proposal is created for the nearest multiple of that value.
Example: Requirement 62, EOQ 50, Mult.qty 25. Creates an order proposal of 75.
3 Number of consumption days: Indicates a summarised requirement from the first shortage day and a number of working days ahead. The number of days to be included in the calculation of the requirements is defined in the Number of cons.days field in the Item file. The proposed quantity will be rounded to the nearest multiple of the quantity defined in the Multiple quantity field in the Item file. 4 Gross requirement: Indicates gross requirements, which means that it will be treated as order rule 1 (lot-for-lot) but without any consideration to warehouse balance. - The Multiple quantity field in the Item file, Manufacturing information is used for order rule 2 to adjust the quantity on order proposals. The proposed quantity will be rounded to the nearest multiple of the quantity defined in this field.
Note: Multiple quantity may also be defined on warehouse level.
- The Planning method field in the Item file, Inventory information must be set to 2 (MRP).
- The Main supplier field in the Item file, Inventory information must be completed for the purchased components. All order suggestions concerning purchase items are connected to the main supplier.
Note: A main supplier may also be defined on warehouse level.
- The EOQ field in the Item file, Inventory management displays the calculated economic order quantity for this item. This is used as a normal order proposal value both for manufacturing and purchase. If Inventory Control is installed and activated, see About economic order quantity (IBS Inventory Control) for information about how to calculate EOQ. If Inventory Control is not installed, then see About calculating EOQ (IBS Stock Control).
- The SST field in the Item file, Inventory management displays the calculated safety stock level for this item. This is used as a normal order proposal value both for manufacturing and purchase.
Structure file
- The Component item field in the Structure file, Bill of material displays the item of which the requirements are calculated based on the requirements of a superior item.
- The Quantity field in the Structure file, Bill of material is used by the material requirement calculation to assess the amount of components needed.
- The Phantom item field in the Structure file, Bill of material controls if the requirements for the phantom component are accounted for in the calculation. If this field is set to YES, the item’s gross requirements are moved to next level in the structure.
- The Allocation warehouse field in the Structure file, Bill of material controls in what warehouse a component will be reserved. This is only used if the Main whs mtrl alloc field in the MFG control file is set to YES.
Prerequisites
- A supply plan version must be set up in IBS Supply Plan. See About supply planning for detailed information.
Working with pull planning
Controlling parameters
The following parameters must be set up in the Item file:
- The Item type field controls how the items are handled in the pull-planning. Proposals for manufacturing orders are created for items with item type 1 and 2, and proposals for purchase orders are created for items with item type 3 and 4.
- The Planning method field defines what function should be used when the order proposals are created. The following methods can be used for pull planning:
3 Priority analysis 4 Shortage analysis, ROP 5 Shortage analysis, min/med/max - The Requirement calc field indicates if the item is to be included in the requirement calculation. If this field is set to NO the item will never be included in the order proposals.
- The Order period field indicates how often you plan the item. The replenishment time can be extended by entering a number of additional days in this field. If, for example, order proposals are created once a week and an item has a replenishment time of 3 days, a value of 2 can be entered in this field to see the requirement for a whole week.
- The EOQ field in the Item file, Inventory management displays the calculated economic order quantity for this item. This is used as a normal order proposal value both for manufacturing and purchase. If Inventory Control is installed and activated, see About economic order quantity (IBS Inventory Control) for information about how to calculate EOQ. If Inventory Control is not installed, then see About calculating EOQ (IBS Stock Control).
- The ROP field in the Item file, Inventory management is used in the shortage analysis for check and set the shortage code during calculation. If Inventory Control is installed and activated, see About reorder point and safety stock (IBS Inventory Control) for information about how to calculate ROP. If Inventory Control is not installed, then see About calculating ROP (IBS Stock Control).
- The SST field in the Item file, Inventory management can be used in shortage analysis as the minimum stock on hand value. If Inventory Control is installed and activated, see About reorder point and safety stock (IBS Inventory Control) for information about how to calculate SST.
- The Multiple quantity field in the Item file, Manufacturing information is used to adjust the quantity on order proposals. The proposed quantity will be rounded to the nearest multiple of the quantity defined in this field. Multiple quantity may also be defined on warehouse level.
Note: For items using the shortage analysis planning method, the order quantity is adjusted to the nearest multiple of this quantity.
Note: This information is not used for items using the priority analysis planning method.
Prerequisites
Prerequisites for shortage analysis
In order to use the shortage analysis functions the following conditions must be fulfilled:
- The Requirement calc field in the Item file must be set to YES.
- The Planning method field in the Item file must be set to 4 (Shortage analysis, ROP) or 5 (Shortage analysis, min/med/max). Note: This information can also be defined on warehouse level.
- The Production/hour field is recommended to update in the Item file or on warehouse level. It enables calculation of estimated workload.
- The Main supplier field in the Item file, Inventory information must be completed for the purchased components. All order suggestions concerning purchase items are connected to the main supplier. Note: A main supplier may also be defined on warehouse level.
In order to analyse the order controlled items (planning method 5) in the shortage analysis, the following must be done:
- Set up the min/med/max inventory table.
- Run the MRP calculation (MRP_RUN) in order to get order proposals/requirements.
- Run the Quantity on hand level calculation (ON_HAND) in order to get shortage code 5 or 7. If it has not been run only shortage code 0 and 1 can be allocated. The job uses a forecast, broken down through the product structures in the material requirements calculation, for the calculation of on hand levels.
Prerequisites for priority analysis
In order to use the priority analysis functions the following conditions must be fulfilled:
- The Requirement calc field in the Item file must be set to YES.
- The Planning method field in the Item file must be set to 3 (Priority analysis). Note: This information can also be defined on warehouse level.
- The Production/hour field is recommended to update in the Item file or on warehouse level. It enables calculation of estimated workload.
- The Main supplier field in the Item file, Inventory information must be completed for the purchased components. All order suggestions concerning purchase items are connected to the main supplier. Note: A main supplier may also be defined on warehouse level.
- The Priority alternative field in the MFG control file controls how the priority value should be calculated. The following values can be selected for priority analysis:
1 MRP order proposal: Material requirement planning (MRP) must have been run. When ordering the MRP order proposal job, the Gross requirement field is of importance. If this field is set to NO, the Order rule field must be set to 4 (Gross requirement) in the Item file for the items. 2 Simple, from consumption: Year forecast from item or warehouse level retrieves and divides with the system control value: number of days/year or, if year forecast is missing, the value is retrieved from periodic statistics 12 month back and divided with number of days/year in Work with companies.
Working with manufacturing orders
Controlling parameters
The manufacturing order type controls:
- What status the order will get.
- If order network will be created.
- How the reporting of material and operations is to be handled.
- What shop floor documents are to be printed.
- If the order should be included in the manufacturing order history after the production of the item.
Prerequisites
- The item to be produced must exist in the Item file.
- The item to be produced must have an item structure defined in the Structure file.
Working with phantom items
Controlling parameters
- The Phantom item field in the Structure file, Bill of material controls if the subassembly is a phantom item.
Prerequisites
- The end item and the components must exist in the Item file.
Working with block orders
Controlling parameters
The manufacturing order type controls:
- What status the order will get.
- If order network will be created.
- How the reporting of material and operations is to be handled.
- What shop floor documents are to be printed.
- If the order should be included in the manufacturing order history after the production of the item.
Prerequisites
- The item to be produced must exist in the Item file.
- The item to be produced must have an item structure defined in the Structure file.
Working with manufacturing group orders
Controlling parameters
The following parameters in the Manufacturing group order type table control the behaviour of the group order:
- The Report on group field controls if the manufacturing orders or operations should be reported from the manufacturing group order.
- The Used from field controls if the group order should be connected to the manufacturing header or operations.
- The Limit type field controls if there should be a restriction to the number of orders added to the group order. The restriction/limit can be based on either order quantity or operation time.
- The Create group field in TIME controls if a consolidated order should be created in IBS Time.
Prerequisites
- Group order types must be set up in the Manufacturing group order type table.
- IBS Time must be installed and activated in the company in which you work if a consolidated order is to be created from a group order.
Working with preliminary manufacturing orders
Controlling parameters
- The Item class field in the Item file controls if preliminary orders can be created for an item. Only items with item class 2 (non-stock item, standard) or 3 (configuration item) result in preliminary manufacturing orders. Note: Manufacturing orders for items with item class 1 (standard, keep in stock) can become preliminary if the user has decided to create the manufacturing order from sales order (no automatic).
- Only manufacturing orders that are created from a sales order or a project order can be preliminary.
Prerequisites
Before the capacity clearance can be used the following is necessary:
- The on-line capacity/workload has to be created. See About work centres and About workload handling for manufacturing orders for instructions.
- The Workload planning type field in the Work centre file has to be updated.
Working with detail planning
Controlling parameters
There are no controlling parameters.
Prerequisites
- Manufacturing order operations must exist in the selected work centre.
- A production technology code must be set up in the Production technology codes table.
Working with batch clearance
Controlling parameters
There are no controlling parameters.
Prerequisites
- Manufacturing orders to be analysed in the batch clearance function must have one of the following statuses:
00 The order is preliminary and has been created from a sales order line or a project element. 05 The order cannot be processed and no reporting is allowed. The manufacturing orders will get status 05 by default if the Batch clearance field is set to YES in the Manufacturing order type table. The status can also be 05 if the Order allocation field is set to YES in the item warehouse for the components. - When releasing a manufacturing order the shortage code for the component must be 3. The shortage code for the subassembly can be either 2 or 3.
Printing shop floor documents
Controlling parameters
The following parameters in the Manufacturing order type table control the printing of the shop floor documents:
- The Direct print of shopfloor documents field controls if the shop floor documents are to be printed directly after the creation of a manufacturing order.
- The Print oper card at field controls if the operation card should be printed along with the other shop floor documents or if it should be printed individually from the detail planning module.
- The Print pallet labels field controls if pallet labels should be printed along with the other shop floor documents. Note: Pallet labels are only printed for items that are defined with automatic pallet creation on item warehouse level.
Prerequisites
- Shop floor documents can be printed for manufacturing orders at status 10, or for orders at status 10 – 40 if the New document field on the manufacturing order header is set to YES.
Working with sub-contract operations
Controlling parameters
- The Subc operation field in the Structure file, Bill of routing controls if the operation is sub-contracted.
- The Order/Return and Update stock on hand fields in the Purchase order type table control if purchase orders can be created directly for a subcontracted operation. The Order/Return field must be set to 1 (order will be produced) and the Update stock on hand field must be set to NO.
- The Purchase order type field in the MFG control file defines a default purchase order type for the subcontracted operations.
- The Pur order descr type field in the MFG control file controls if the operation description or the parent item description should be added to the purchase order line for subcontract operations.
- The Always new pur order field in the MFG control file controls if a new purchase order should be created for each subcontract operation line or if one purchase order should be created for all released subcontract operations for one supplier.
Prerequisites
- A purchase order type must be set up in the Purchase order type table with the Order/Return field set to 1 (order will be produced) and the Update stock on hand field set to NO.
Working with operation reporting
Controlling parameters
Reporting of scrapped items
The following parameters control if scrapped material can be reported:
- The Backflushing material: At operation report field in the Manufacturing order type table controls if used material should be backflushed when an operation is reported with quantities. This field must be set to YES for scrap reporting.
- The Floor stock code field in the Item file, Manufacturing information controls if the item is backflushed. This field must be set to 1 (backflushing item) for scrap reporting.
- Scrap reporting is only allowed if the manufacturing order status is 10 or higher.
Reporting of re-usable items
The following parameters control if re-usable material can be reported:
- The Backflushing material: At operation report field in the Manufacturing order type table controls if used material should be backflushed when an operation is reported with quantities. This field must be set to YES for reporting of re-usable items.
- The Floor stock code field in the Item file, Manufacturing information controls if the item is backflushed. This field must be set to 1 (backflushing item) for reporting of re-usable items.
- The Re-usable material field in the MFG control file controls if reporting of re-usable material is allowed. This field must be set to YES.
- The Re-usable field on panel Manufacturing order maintenance, Material must be set to YES for the component. Note: This field can also be set to YES in the Structure file, Bill of material for the component. However, the value entered for the manufacturing order bill of material overrides the value entered in the item structure.
Milestone reporting
The following parameters control if milestone reporting can be used for operation reporting:
- The Reporting operation field in the Structure file, Bill of routing controls if an operation functions as a reporting point. This field should be set to YES for the reporting operations and to NO for the operations that are to be backflushed when the next operation is reported.
Backflushing at operation reporting
The following parameters control if material can be backflushed during operation reporting:
- The Floor stock code field in the Item file, Manufacturing information controls if the item is backflushed. This field must be set to 1 (backflushing item).
- The Backflushing material: At operation report field in the Manufacturing order type table controls if used material should be backflushed when an operation is reported with quantities. This field must be set to YES.
- If the item is defined as a location or batch item the Backflush location/batch item field in the Manufacturing order type table must be set to YES.
Product reception at operation reporting
The following parameters control if products can be received during operation reporting:
- The Reception at last operation field in the Manufacturing order type table controls if material should be received when an operation is reported with quantities. This field must be set to YES.
Time/quantity calculation at operation reporting
The following parameters control if time and quantities can be calculated automatically during operation reporting:
- The Reporting calc field in the Work centre file controls if time or quantity is calculated at operation reporting. Time will be calculated if this field is set to 2 (Time) and an approved quantity is reported. Approved quantity will be calculated if this field is set to 3 (Approved quantity) and an operation time is reported.
Prerequisites
- A manufacturing order must exist.
- The manufacturing order must be at status 20 before reporting is allowed if the Allow rep without print shop floor field is set to NO.
Working with NCC reporting
Controlling parameters
- The manufacturing order type controls how the reporting should be done. The reporting must be done for the last operation if the order type has the Reception at last operation field set to YES. Note: This does not apply for NCC reporting at product reception.
Prerequisites
- Conformity criteria must exist in the Item conformity criteria table.
- Stock categories must exist in the Stock category table.
- Reason codes must exist in the Non-conformity reason table.
Working with quality control reporting
Controlling parameters
Conformity criteria
The conformity group that is connected to the item on the manufacturing order is defined in the Conformity group field in the Item file. From this group one or several conformity criteria might have been connected to the item in the item structure, either on header level or in the bill of routing.
See Define conformity criteria for an item structure for more information.
Quality control reporting values
The quality control, which is based on the conformity group that is connected to the item, can be performed either during operation reporting or product reception. In the item structure you can specify if, where and when the control should be performed. This can be specified either on structure header level or from the bill of routing:
- The QC always field in the item structure defines if a quality control always should be performed during manufacturing operation reporting and/or reception.
- The QC interval days field in the item structure defines the number of days that must pass before the next quality control is performed. The next quality control date is calculated by using the calendar defined in the MFG control file.
- The QC interval time field in the item structure defines the number of reported hours that must pass before the next quality control is performed. The quality control first checks the machine time, and if no machine time is entered the run/labour time is used. Note: This field is only valid for operation reporting
- The QC interval rep/rec field in the item structure defines the number of reported operations or received manufacturing orders that must be handled before the next quality control is performed.
- The QC interval qty field in the item structure defines the quantity in stock unit that must be reported or received before the next quality control is performed.
See Define quality control values for an item structure for more information.
Prerequisites
- Conformity criteria must be defined for the item in the item structure.
- The MQC_REC (Manufacturing quality control at reception) function must be installed and activated.
- The MQC_OPER (Manufacturing quality control at operation reporting) function must be installed and activated.
Issuing manufacturing order material
Controlling parameters
- The Floor stock code field in the Item file, Manufacturing information controls how items are issued. This field must be set to 2 (normal warehouse item) if material is to be issued manually.
- If the item is defined as a location or batch item the Backflush location/batch item field in the Manufacturing order type table must be set to NO if material is to be issued manually.
Prerequisites
- The status of the manufacturing order must be at least 10 before issuing of material start. The status must be 20 if the order type requires printing of shop floor documents before the material issue.
Receiving manufacturing order products
Controlling parameters
- The Batch field in the Item file, Inventory information controls if an item is batch handled.
- The Serial no tracking field in the Item file, Inventory information controls if an item is serial controlled.
- The Aut pallet creation field in the Item file, Warehouse management controls if pallets should be automatically created when a put away suggestion is generated.
- The Pallet type field in the Item file, Warehouse management controls what pallet type to be used when pallets are automatically created.
- The Quantity in pallet field in the Item file, Warehouse management controls the number of stock units in the default pallet.
- The Print pallet labels field in the Manufacturing order type table controls if pallet labels should be printed along with the other shop floor documents. Note: Pallet labels are only printed for items that are defined with automatic pallet creation on item warehouse level.
Prerequisites
- IBS Warehouse Management must be installed and activated in the company and for the item that is to be pallet handled.
- A pallet type must be set up in the Pallet type table.
- A location size must be activated for the pallet type.
Working with downtime reporting
Controlling parameters
There are no controlling parameters.
Prerequisites
- A work centre must be set up in the Work centre file.
Reporting other costs
Controlling parameters
There are no controlling parameters.
Prerequisites
- A manufacturing order must exist for which other costs can be reported.
Working with manufacturing batch input
Controlling parameters
The following controls if the Inventory transaction error file contains erroneous transactions:
- The transaction has been created based on an external operation reporting transaction (backflushing or reception at last operation).
- The manufacturing order, to which the transaction belongs, is defined with reception at last operation in the Manufacturing order type table.
- A transaction error was detected during the reporting of the last operation.
Prerequisites
- Reporting transactions must be transferred from IBS Time or an external reporting system.
Working with workload
Controlling parameters
- The Workl planning type field in the Work centre file defines if run/labour time or machine time is used as a base for the workload calculation.
- The Write down method field in the Work centre file defines how the write down of workload should be performed for the manufacturing order.
Prerequisites
The following information must be entered in the Structure file, Bill of routing before workload can be created:
- The Queue time field can be used on all operations, except if previous operation is defined with an overlapping type.
- The Set-up time int field should be completed for workload.
- The Run and labour time or Machine time field should be completed. One of these times is used as the “real” workload time, but workload is calculated for both these times. Which times to be used as the real calculation base is controlled by the Workl planning type field in the Work centre file.
- The Transport time field can be used on all operations, except if the operation is defined with an overlapping value.
- The Overlapping type field indicates an overlapping to the next operation. It can be either based on quantity or percentage of workload time. In combination with overlapping value it’s used to calculate overlapping of operation planning dates.
- The Overlapping value field should contain a value referring either to a quantity or a percentage of workload time depending on the overlapping type. It defines the overlapping to the next operation.