Job Shop Control

The 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.

• Reporting as completed

  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.

• Scrap and yield

  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.

• Put away to quarantine

  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.

• Planning production orders

  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 Purchase Orders

  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.

• Executing subcontracted operations

  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.

• Customer furnished materials

  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.

• Material issue

  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.

• Backflushing

  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.

• Floor stock

  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

  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

  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

• Input / output control

  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.

• Order grouping

  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.

• Order-block planning

  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).

• Production order splits

  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

  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.

• Schedule Viewer for Job Shop Schedule Runs

  The Schedule Viewer displays the workload of the machines in a critical machine group for the Job Shop Schedule Runs.

• Machine Group Utilization workbench

  You can use the Machine Group Utilization workbench to view the situation of the shop floor. You can view the information related to the capacity, order lateness and progress.