Define Operations and Material Consumption for a Service

Use this procedure to define each step in a service that you have defined. Each step consists of an action that requires a specific amount of time to perform. In some cases, there is also a material consumption to describe. This document explains how to define the sequence of operations. The result is called a product structure.

Use this document when you have defined a service and wish to define how long it takes to perform and what materials are used.

Outcome

A product structure is described for each selected service. This product structure contains information about where in a facility a job is to be performed, the amount of time the job is supposed to take, and the materials that are normally consumed.

The product structure is used when a work order is created. The product structure can be viewed and changed in 'Work Request. Open Line' (MOS171) and 'Work Order. Open Line' (MOS101).

Information about the product structure is stored in these tables:

  • Product database materials, MPDMAT
  • Service on materials and operations, MPDSRF
  • Product database operations, MPDOPE

Before you start

  • A service must be defined in 'Service. Open' (MOS300).
  • An item must be defined in 'Item. Open' (MMS001).
  • Items must be connected to a warehouse in 'Item. Connect Warehouse' (MMS002).

Follow these steps

  1. Start 'Service. Open' (MOS300/B).

  2. Select an appropriate sorting order.

    The recommended alternatives are: 1-'Product number', 2-'Service'.

  3. Select option 12='Product Structure' for the service to which you wish to connect materials and operations. Program 'Product. Connect Materials/Operations' (PDS002/U3) is then displayed.

  4. Select F13 to display the settings panel.

    Panel (PDS002/PQ) is used to determine which fields are displayed during entry.

  5. On the P and Q panels, set these parameters:

  6. Specify components that are not in the master file - No.

  7. Verify operation on material line - Yes.

  8. Select a default warehouse.

    You can select the other parameters, if desired. If not selected, some fields are not displayed.

  9. Press Enter to return to the U3 panel.

Add operations to a service

  1. Specify an operation number, a work center and, if applicable, a start date.

    Select New record to display (PDS002/G).

    The operation number can be, for example, 1, 2, 10, or 20.

  2. On the G panel, specify an end date for the operation, a description, the run time with a unit of measure, quantity, and setup time, both internal and external (optional fields).

  3. Specify whether the planned run time must be regarded as total time, regardless of the quantity specified.

  4. Specify the number of people that are planned to perform the operation, the number of machines that are used in the operation, and how many people are planned to set up the operation (optional fields).

    The number of people planned for an operation form the basis for load and lead time calculations. This works if the work center is planned based on labor time and not machine time.

  5. Specify how the operation is to be processed if it belongs to a phantom routing (optional).

  6. Specify a scrap percentage, document ID, how orders for subcontract operations must be created, and sub service (optional fields).

    Scrap percentage can be used to indicate the expected scrap. Primarily, this is used for manufacturing.

  7. Specify option percent, setup scrap, tool number and whether to create overload (optional fields).

    Press Page Down to display the H panel.

  8. The lead time offset indicates the number of days before the finish date that an operation must start.

    This field is used differently based on the 'MO lead time method' set in 'Item. Connect Facility' (MMS003). The alternatives are 0 for manual and 1 for automatic.

    This can be overriden in 'Work Order Type. Open' (MOS120), parameter 197.

    If alternative 2 is selected, the 'Lead time offset' field is available to specify a manual number of days.

    These are the alternatives:
    • 0 - Acc to MMS003/F
    • 1 - Manual - Override MMS003/F
    • 2 - Manual - Lead time offset

    Select alternative 0 to calculate operation times according to the 'MO lead time method' on (MMS003/F), whether manual or automatic.

    Select alternative 1 to override the 'MO lead time method' on (MMS003/F) and set operation times manually. This tells the system to behave as if the 'MO lead time method' on (MMS003/F) is 0.

    Select alternative 2 to behave as in Manufacturing, using the manually set lead time offset on each operation (days before finish). When this alternative is used, the time between the start date and the finish date on the WO header is equal to the longest 'Lead time offset'. The operations are then calculated by using the lead time offset to determine when to start. The finish date and time for each operation are calculated based on the runtime/production days.

  9. On the H panel, specify whether the operation must be considered in lead time calculations.

    Standard operations are normally included in lead time calculations.

  10. Specify the required skill, the required skill for inspection, the unit price, the setup price, and the time rate (optional fields).

    The unit price is the price for each operation or the price paid for subcontract operations.

    The time rate is the fixed element of a time/piece rate. The field only needs to be filled in if time references are not used.

  11. Specify the pay element (optional if the pay module is installed), and the number of labor tickets to be printed for each operation.

  12. Specify the initial weight of the product, the operation volume, a multiplication factor and an operation cost multiplier (optional fields).

  13. Specify whether work orders must be closed when the last operation is reported and whether operations must be reported automatically.

    Work orders can be automatically closed when the last operation is reported on an order.

  14. Specify a formula and a formula result for calculating the operation run time (optional and intended for manufacturing).

    Formulas are used to update, for example, run times of operations and are defined in 'Formula. Open' (CRS570).

  15. Specify the supplier number of the subcontract supplier that performs the operation, the ID of the next supplier and whether this operation demands that all subassemblies are finished before it is started (optional fields).

    Press Enter to finish.

    Note: From (PDS002), use related option 65='Subcontracting Supplier' to display 'Subcontracting. Connect Supplier' (MOS018). Here, you can manage the preferred supplier on different levels compared to (PDS002/H).

Add material to an operation

  1. Start 'Service. Open' (MOS300/B).

  2. Select an appropriate sorting order.

    The recommended alternatives are: 1-'Product number, 2-'Service'.

  3. Select option 12='Product Structure' for the service to which you wish to connect materials and operations. Program 'Product. Connect Materials/Operations' (PDS002/U3) is then displayed.

    Note: You can also start (PDS001) and specify option 11=Material/Operation to display (PDS002/U3).

  4. Select an appropriate sorting order.

    The recommended alternatives are: 3-Sequence no., operation, work center, or higher.

  5. Specify a sequence number to sequence the parts, an operation number to connect the material to an operation, and the component number.

    Select New record to display panel (PDS002/E).

  6. On the E panel, specify a quantity used in the service and the total quantity in the product, as well as the position where it might be found (optional fields).

  7. Specify an option percentage and the normal waste if applicable.

  8. Specify a sub-service, if one exists, a description and a technical reference (optional fields).

    Press Page Down to display panel (PDS002/F).

  9. On the F panel, specify whether the operation results in a usable by product.

    For maintenance, this field must be set to 0.

  10. Specify whether the component must be considered as lot controlling for the current product (only selected for manufacturing).

  11. Specify whether the material must be regarded as critical material.

    If the material is defined as critical, it is included in component availability checks performed in 'Availability. Simulate for Material' (MMS085).

  12. Specify whether the material must be considered in material requirement calculations for the product, normally set to 1-'Yes'.

    Press Enter to finish.

    Materials in standard operations are normally included in material requirement calculations.

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