| Job Shop ControlThe job shop control module handles the creation of production orders, planning
of production orders, and the procedure related to the execution of these
orders. You can manually create
and modify production orders in the Job Shop Control module. To create production orders automatically, you must use Enterprise Planning. Production typologies Job Shop Control handles the actual manufacturing of items. Production orders
can be classified and controlled in several ways, depending on the level of
customization required for the item or order and the item. The production typologies possible in Job Shop Control are: Fully customized, derived from a standard
item In this situation a standard item is fully customized to meet
customer requirement. This includes customized BOMs, routings, and cost
structures that are based on the product structure of the standard item as a
template. Afterwards engineering can take place on the customized structure.
Through a PCS project, the sales order is then transferred to an job shop
order. This situation applies to Engineer-to-Order/Make-to-Order. Through the
PCS project code, the job shop order is pegged to the SLS order. Fully customized, derived from a generic
item A sales order is available for a standard generic item, but
not FAS. This item is fully customized. Planning, forecasting, and material
explosion will be performed in Enterprise Planning. This situation applies to
Engineer-to-Order/Make-to-Order environments with relatively low
volumes. Derived from a generic item, without
project The production typology is related to the previous one
however this situation applies to high volume production environments. For
these a product configurator can be used without using PCS projects. The anonymous production, standard item This typology describes the situation in which production is
purely anonymous. Items are produced to stock. Ordering systems can be SIC,
MRP, MPS, or manual, for the manufacturing execution on JSC. The only
difference in JSC compared to customized production is that no project code is
available. Therefore, the JSC order is not pegged to an SLS order. Fully customized, customized item. Customized production is started from a product configurator
and is not derived from a standard item. A project code is printed on the order
documents. The JSC order is pegged to an SLS order. This is applicable in real
engineer-to-order environments where the design of the item starts from scratch
and is based on customer requirements.
Production orders control A production order is comprised of the order to produce an
item and the conditions under which manufacturing takes place, such as the
routing that is used, the delivery date and the order quantity. You can monitor the progress of the production progress,
for example, the production orders, quantities, and operations that are
complete, and the quantities that are processed in specific
operations. In manufacturing processes it is often necessary to plan
the production of more product than you actually need, because some of the
product may be outside specification. Some of the components can also break or
be unsuitable for production. This effect is modeled by means of scrap and yield. During the production process some end products may not be
compliant with the desired specifications. When a defect on the manufactured
item is detected during an operation step in the production process, you have
the option to send the defective item to a quarantine location to be reworked
at a later date. Production order planning provides the facility to modify
and preplan the production order. The planning is a process of determining the
start and end dates of the individual operation and production order. When the
production order is planned, the lead-time of the operations and the production
order is calculated. The load on the corresponding machines and work centers is
also calculated and displayed. Subcontracting is a common practice in manufacturing
industries. Part of a production process is subcontracted for several
reasons: - A specialized operation can be needed for which the
company does not have the proper facilities.
- Enough capacity is not available.
- The work is large and could be expensive if carried out
internally.
Production orders executed for the manufacturer are
indicated as "subcontracting" production orders. You can receive materials
owned by the manufacturer for these orders. Those items are stored against a
certain value using the current valuation logic. You can issue items to a
subcontracting production order. The actual costs of those items are zero when
they are consumed in a production order. The WIP of a subcontracting production
order is partially owned by the manufacturer, this is visible to the user. A customer furnished material is material that is provided by the customer for use
on their project. Quantities and deliveries are agreed upon with the
customer. In the Items (tcibd0501m000) session, the order system must be Planned for the customer furnished material. Optionally, you can use customer furnished materials in
combination with demand pegging or project pegging. The entering of issues as part of the order procedure for
production orders is required to issue the necessary materials from the
warehouse to the job shop. Issuing can be done manually or by the system while
the estimate is being built up. When backflushing applies, issuing of inventory
is automatically performed. The automatic issue of materials from inventory, or
accounting for the hours spent manufacturing an item, based on theoretical
usage and the quantity of the item reported as complete. A stock of inexpensive material present on the shop floor
that can be used in production without recording each issue of material
individually. Floor stock is not backflushed and is not part of the estimated
costs. To account for floor stock materials, a surcharge is added to the
standard cost of an end item. A Kanban triggers the supply of floor-stock items
to the job shop. You can create a warehousing order of type JSC Production in which you determine from which warehouse and to what
work center the material must be shipped. Shop floor warehouses are a special kind of warehouse that
store and control the materials needed for production. A shop floor warehouse
is linked to a work center by which materials needed for operations can be
pulled from inventory in the shop floor warehouse linked to that operation for
example, a location in the line. Production order costing deals with the production order
costs for all items of all production types whose production orders are handled
in the Job Shop Control module. The costing functionality for order costing of standard items and
customized items is the same. These can be calculated: - Estimated order costs
- Actual order costs
- Production results
You can use input/output control to judge how efficiently
your machines or work centers are operating. You can compare actual input with
planned input to find out when there is not enough work at a work center or
machine, which leads to poor productivity. You can compare actual output with
planned output to discover problems at a work center or machine. A Job Shop Control order group is a group of production orders, defined by the
user. You can add production orders individually, or specify criteria to ensure
the orders with common features are grouped. After a group is formed, you can
use it to perform actions on all production orders within the group at the same
time, for example, report orders as complete, printing order documents, or
close orders. To optimize the use of the various machines available for
the production process in a factory and minimize changeover due to other
product characteristics, functionality is available to sort production orders
based on set-up classes (such as color). A production order split allows you to split in-process
production orders into multiple production orders. You can select the split-off
quantity that goes to the new child order or split off rejected
items. A split can be required in situations such as the
following: - The total order quantity cannot be completed in time due
to capacity issues
- Insufficient material is available to complete the total
order quantity in time
- A part of the total order quantity is nonconforming,
expedited, or delayed
Costing breaks are defined to override a project peg
distribution of actual supply orders and move the related costs to different WBS nodes on the same project. In the bill of material (BOM), costing breaks can be applied to routings,
operations, work centers, or cost types. Multiple costing breaks can be applied
to a specific BOM.
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