1. 1 Managing MO’s with OBPM How to use Browser/PowerLink technology to revolutionize Manufacturing Orders Jim Simunek, CPIM Jim.Simunek@cistech.net

2. 2 Introduction Order Based Production Management (OBPM) allows for Manufacturing Order: –Create –Change –Receipt (RM) production –Complete, material & labor –Cancel (status 10 orders) –Close (both Force & Normal)

3. 3 Introduction All activity is ‘immediate update’ (i.e. no batches to close and update) Templates can minimize the amount of data entry MRP and Reorder Report recommendations can be used to create MO’s and/or PO’s Can create MO’s from Customer Order line items

4. 4 Introduction This presentation has been created using Release 7 (PowerLink) Most functions are available at the R6 level also This presentation does not address Repetitive Schedules –Schedules are only available for inquiry in Browser/PowerLink

5. 5 EPDM Impacts (R6 & R7) When using EPDM, MO’s are kept by site Site Master file controls –Work List default values –Order Closeout options –Work Center Analysis report default values With PDM, data in Site Master is maintained in PC&C tailoring questionnaire Order Close & Purge and WIP Value report is by site

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9. 9 EPDM Use ‘Site Host Jobs’ to create Work List reports (can still use Green Screen also)

10. 10 Planner File OBPM has a ‘Planner’ file to create a code file of valid planner numbers

11. 11 Planner Numbers Item Balance (Warehouse) record holds the default planner number for the item All MRP and MPSP reports and work (green screen) screens sort primarily by planner number Planner number is copied into Manufacturing Orders for reports and subsets One person can be responsible for multiple planner numbers

12. 12 Planner From the Planner screen, you can display all MO’s associated with a planner

13. 13 Questions?

14. 14 Creating MO’s Template controls initial fields that are displayed:

15. 15 Creating MO’s With Cards, there is the ability to: –Pre-assign batch/lot number –Maintain the component allocations –Maintain operations –Add Miscellaneous Charges –Link MO to CO –If using EPDM, copy an Alternate Processes BOM and Routing to the MO

16. 16 Alternate Processes EPDM allows for the creation of multiple ‘processes’ for the same item – i.e. alternate bills of material and/or routings When adding the MO, do NOT check the ‘Include Primary BOM’ and ‘Include Primary Routing’ boxes ‘Import’ button on Component and Routing cards allow for Alternate Process to be chosen

17. 17 Creating MO’s When ‘Create Order’ button is pressed, MO is added (i.e. no ‘Order Release’ required) Same files as Green Screen are created: –MOMAST – header information –MODATA – Component Allocations –MOROUT – Operations –MOMISC – Miscellaneous Charges Order is added at Status 10 – Open, no Activity

18. 18 MO Status Codes Order Status 10 – Open, Not Started 40 – Activity Reported 45 – Material Complete 50 – Labor Complete 55 – Both Material & Labor Complete 99 - Cancelled Operation Status 00 – Inactive, labor cannot be reported 10 – Open 30 – Started 40 – Operation Complete

19. 19 Material Transactions At the present time, can only report Production Receipt transactions through Browser/PowerLink When reporting RM transaction, if there are controlled floorstock components, Planned Issue (IP) transactions will be created Pick Complete, Planned Issue, Unplanned Issue, Component Return and Scrap transactions are not available

20. 20 Statusing MO’s Can display open MO’s and PO’s for component parts allocated to an MO

21. 21 Labor Reporting Labor is not reported through Browser/PowerLink Labor can be reported through: –PC&C – green screen labor entry –PM&C – Job ON and OF transactions –PaperLess – feeds PM&C Per Operation, report –Time spent: Set-up, Run and/or Machine –Quantity Complete (good) –Quantity Scrapped –Operation Complete

22. 22 Labor History Browser/PowerLink will display labor history transactions PC&C Control File determines if Labor Reporting history is kept –If using EPDM, Site record holds Labor History question History is kept regardless of what application is used to report labor History is stored in files MOTRAN (open MO) and MOHTRN (MO History)

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24. 24 Production Receipt (RM) Can report Production Receipt (RM) transactions with OBPM Template controls fields that will be displayed If Controlled Floorstock Components exist, they will be issued (IP transactions)

25. 25 Receipt Template

26. 26 Backflush Components

27. 27 MO Transaction History Can display transaction history for an MO:

28. 28 Completing MO’s Use OBPM to Complete: –Material (takes MO to status 45 or 55 if Labor has been previously completed) –Labor (takes MO to status 50 or 55 if Material has been previously completed)

29. 29 Material Complete If quantity ordered has not been completely received, ‘Receipt of Material’ card will be displayed to allow RM transaction Controlled Floorstock components will be issued ‘Material Complete’ card allows for input of Reference, Reason and Date If operation scrap has been reported, controlled floorstock components for scrap quantity will be issued

30. 30 Material Complete

31. 31 Labor Complete From ‘Maintain’ menu, Labor can be reported as complete Reference and Reason codes can be entered ‘Incomplete’ Operations (i.e. Operation Status not equal to 40) can be displayed and completed –Any incomplete operations will be taken to status 40 when Labor Complete is reported

32. 32 Labor Complete

33. 33 Labor Complete – Incomplete Oper.

34. 34 Questions?

35. 35 Select MO for Closeout Can select MO for either normal or force close –Status 55 (Complete) orders have normal close –Less than status 55 orders must be force closed Must select orders for closeout one at a time –If MO’s are taken to Complete (55) status, may want to use PC&C green screen to select MO’s for close (more efficient) Closeout selection does not change MO status Can Re-Open an order that has been selected for close

36. 36 MO Close

37. 37 Production Facility Can display all MO’s scheduled to go through a certain Facility This is useful if you have outside operations and have made the vendor a Production Facility From the Production Facility list, click on a facility, then ‘Display’, then ‘MO Operations Where Used’

38. 38 Facility Where Used

39. 39 MO Operation Where Used

40. 40 Create MO from CO Can use CO line items to create MO Will tie the CO to the MO Will use CO quantity and Manufacturing Due Date for MO With PTF download, RM transaction for MO will create discrete allocation for CO (must be in a controlled warehouse)

41. 41 Create MO from CO

42. 42 Create MO from MRP Can Create MO’s from MRP recommendation file:

43. 43 Create MO from MRP From MRP Recommendation window, use ‘Customize’ →’Preferences’ to set screen to immediate update

44. 44 Component Availability From MRP Recommendations, you can: –Highlight multiple planned MO’s (Control + click) –Check component availability

45. 45 Check Component Availability

46. 46 Check Component Availability

47. 47 MO Create from MRP Recommendation

48. 48 Summary OBPM provides much easier access and reporting to MO’s Ability to Create, Maintain, Cancel, Receive, Complete and Re-open makes it much more ‘user friendly’ to report against MO’s Ability to display MO’s by Planner or Work Center provides better ‘status’ information MRP Recommendations provides component availability capability