Report Operation Time and Scrap

This document explains how you manually update a manufacturing order with the number of produced items and completed work, and how you can change and register unit prices and piece rates.

In addition, there is a system capability of using the received quantity for a manufacturing order (MO) and calculating the operation times based on the operational data entered for the MO. Operation times will be accumulated for each receipt until the order is completed. This is particularly helpful in industries that produce goods, such as milk, where manufacturing can be a very fast process with multiple instances of output reporting throughout the day. The manufactured quantity on a MO report receipt (i.e. Manuf qty field on PMS050/E) is used to automatically calculate the operation times for that production receipt.

Note: The automatic calculating of operation times applies only for those operations in the manufacturing order containing an Auto-reporting (AURP) value of '3'. Operations set to an Auto-reporting value of '0' must have operation time manually reported for them in 'Manufact Order. Report Receipt' (PMS070).

Outcome

The produced and scrap number of items on the manufacturing order has been updated.
The status on the operation has been raised to 70 or 90.
The time used to complete the operation is updated.
Work-in-process (WIP) is updated.
The information is used in accounting, such as WIP (work-in-process) follow-up.
Previous operations can be reported automatically.
Issue of material is reported automatically. See the document Issue Materials.
For work center-related operations with an automatic operation reporting setting of '3 Yes, based on reported quantity', the need for manual reporting is eliminated. All operation times with an Auto-reporting setting of 3 are calculated and reported automatically by the system when the manufacturing quantities are received.

All transactions are stored in the 'Manufacturing Order-operations/ transactions' (MWOPTR) file.

The load is reduced when the operation has been reported.

When an operation with special quality demand has been reported, a control can be performed and reported in 'MO Operation. Report Inspection Result' (PMS085/B).
After reporting, a manufacturing order can be flagged as completed and approved in 'Manufact Order. Report Receipt' (PMS050). A manufacturing order with special quality demands can be flagged as completed after necessary controls in 'Quality Inspected Item. Put-away' (PMS130).
The information can be transferred to the pay system and be the basis for the payment of salary.

Before you start

All conditions listed in Define Settings for Reporting of Operation Time on Manufacturing Order should be fulfilled.
The work center where the work is performed should be defined for manual operation reporting in (PDS010).

Follow These Steps

Start 'MO Operation. Report' (PMS070).
On the A panel of PMS070, select the 'Report child orders' check box to report operations for the parent order and its associated process child orders or pack child orders. If the check box is not selected, only the parent order is reported.

Note: When this check box is selected, the system validates that the MO entered is a parent order in the Order Relationship (MWPREL) table.
Specify a facility and product number.

If you specify an MO number, you will get the product number automatically.
Select one of the following:
- If you only have one operation to report, fill in one of the following fields:
  - Operation number
  - Reporting number
  - Production lot number.
    The unit of measure that contains items from a special lot can be reported.
  Then you go directly to the E panel by pressing Enter and continue with step 6 to complete information for all time types.
- If you want to report several operations, you fill in a value in one or several of the following fields:
  - Schedule number
  - Reported type
    On the P panel, you decide whether this field should be displayed on the A panel.
  - MO number
  - Reporting date.
Check, and change if necessary, facility, schedule number and reporting date on the B panel.
Perform this step.
- If all the information is correct you can:
  - Approve all operations by pressing F14. Continue with Specify Prices.
  - Approve separate operations by marking the row and selecting alternative 12=Confirmation. Continue with Specify Prices.
- If the information needs to be completed and/or changed before you can approve the operation(s) on the E panel, press Enter and continue with the next step.
Select and continue with one of these reporting types on the P panel.
- To select reporting on labor run hours, machine run hours and setup time or to select reporting on labor and machine run hours, see Complete Information for All Time Types.
- To select reporting on setup time, see Complete Information for All Time Types, Complete Personnel Information and Complete Information for Setup Work.
- Complete Information for All Time Types
  Enter the following information for all time types:
  - Produced quantity
    Note that scrap quantity should be included in produced quantity.
    
    The quantity that is left to produce on the operation is automatically suggested in the field.
  - Scrap quantity
  - Operation completed
    This field must be selected on the P panel to be displayed. If there are no more units left to produce, you flag the MO as completed. The remaining quantity will then be changed to zero. If the produced quantity is greater than or equal to the ordered quantity, the field will be filled in automatically.
  - Reject reason
  - Scrap source work center
    The field is used if the scrap has been caused by a work center that is different from the work center that is reporting the operation.
  - Costing type
  - Transaction date
  - Transaction time
  - Planned number of workers - setup
    Enter the number of people that are planned to participate in preparations for the current operation.
  - Rework.
    Select if a previously processed product was reworked in the current operation.
- Complete Personnel Information
  Complete and, if necessary, change the data of the people that have performed the work:
  - Employee number
    If you want to report several employees, select 'Report employee number' (F14) to start 'MO Operation. Report Employee Number' (PMS075). The time for labor run hours and setup work is reported per employee in 'MO Operation. Report Employee Number' (PMS075). Corresponding fields in 'MO Operation. Report' (PMS070) will be blocked.
  - Shift
  - Planned number of workers
    This is the number of people planned to perform the operation. The field can only be filled in for labor hours. It may not be filled in for machine hours. The information has been used for scheduling the operation.
  - Resource
    Enter the type of machine that the work is performed on.
  - Deviating work center.
    Enter the work center that actually performed the operation if it differs from the planned work center.
    
    Note: A work center selected as a Deviating work center cannot be auto-reported. This is true even if it has an Auto-reporting (AURP) field value of '3'. The system will ignore its AURP value and use the manually reported operation times for the transaction.
- Complete Information for Labor Time
  Check and, if necessary, change the following fields:
  - Used labor run hours
    If the fields for labor and machine run hours are closed, the time is calculated from the number of items produced. You choose which fields you want to be able to fill in on 'Work Center. Open' (PDS010).
    
    If the field for labor run hours is closed but the field for machine run hours is open, the labor run hours are calculated from the machine run hours.
  - Used machine run hours
    If the fields for labor and machine run hours are closed, the time is calculated from the number of produced items. You choose which fields you want to be able to fill in on 'Work Center. Open' (PDS010).
    
    If the field for machine run hours is closed but the field for labor run hours is open, the machine run hours are calculated from the labor run hours.
  - Run disturbance.
    Enter the type of disturbance that occurred during production. You can send a message or a letter to the M3 mailbox if some type of disturbance occurred.
- Complete Information for Setup Work
  Check and, if necessary, change the following fields:
  - Used labor setup time
    If the fields for labor and machine setup time are closed, the time is calculated from the number of produced items. You choose which fields you want to be able to fill in, in 'Work Center. Open' (PDS010).
    
    If the field for labor setup time is closed but the field for machine setup time is open, the labor setup time is calculated from the machine setup time.
  - Used machine setup time
    If the fields for labor and machine setup are closed, the time is calculated from the number of produced items. You choose which fields you want to be able to fill in in 'Work Center. Open' (PDS010).
    
    If the field for machine setup time is closed but the field for labor setup time is open, the machine setup time is calculated from the labor setup time.
  - Setup disturbance
    Enter the type of disturbance that occurred during production. You can send a message or a letter to the M3 mailbox if some type of disturbance occurred.
Continue with specifying prices and piece rate, or press F3 to finish.
To specify prices, press Enter to get to the G panel. The G panel shows prices and piece rate earnings.

You must have selected the G panel on the P panel.
Check the fields on the G panel, and go back to the E panel if you need to correct any of the information.
Enter values in the following fields:
- Unit price
- Setup price
- Pay element
  Pay element is the type of wage assigned to a task, such as setup work or overtime. Pay elements must be entered when a connection to Payroll Administration (PAY) exists. When entering operations, the pay element from the work center is displayed by default.
- Time rate
  The field indicates the fixed part of a combined time/piece rate. The time rate is used as information on the labor ticket.
- Total amount
  The total amount is an alternative that is used instead of having the system calculate the amount using the setup or unit price.
- Remark
Press F3 to finish.
Optionally, enable auto-reporting of operation times upon production receipt.

Note: The Automatic Receipt (AUIN) check box value must be set to '0' (Off) if the Auto-reporting (AURP) field is '3' in the following programs: 'Work Center. Open' (PDS010/F), 'Product. Connect Operations' (PDS002/H), 'Manufact Order. Open Lines' (PMS101/G)
1. On panel F of 'Work Center. Open' (PDS010), select a value from the Auto-reporting (AURP) field.
  
  Note: You must select a value of '3' to enable the auto-reporting functionality. All operation times with an associated Auto-reporting setting of '3' are calculated and reported automatically by the system when the manufacturing quantities are received.
2. Open 'Product Structure. Open' (PDS001) to define the product itself.
3. Open 'Product. Connect Materials/Operations' (PDS002).
4. On panel U1 of PDS002, create the recipe by defining the components and operations required to manufacture the product.
  
  Note: When an Operation number is added to the recipe, the Work Center required to carry out the operation is selected. The Auto-reporting (AURP) value and other details are inherited in the recipe from the Work Center (PDS010).
5. On panel H, the default value for the Auto-reporting field for the work center can be changed.
  
  Note: If the Auto-reporting (AURP) field has been changed, the system evaluates all the operations to determine if there is a conflict. If so, the system displays the error message: 'Auto-reporting field must be set to 0 or 3 for all operations.'