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Exhibit B: Expert Configurator Multi-Level Example >
Manufacturing Rules
Manufacturing Rules
The two most common types of rules available for generating manufacturing orders are the Component Requirement and Labor Requirement rules.
· Component Requirement rules create component requirements depending on the sales order options selected, and attach them to a manufacturing order. The user can also decide to use the standard bill of material of the configured product. In a multi-level environment, there must be a manufacturing component requirement rule for each sales order configured component rule. In our example, we require the London model to have a bookshelf and the Stockholm model to have a disk file. We do not create any other component requirement rules such as ones for the desk size, color, or microcomputer table. For the drawer, we require a certain quantity of the part BOARD depending on the value of the option DRAWERSIZE. We also have rules to require a pencil cup if one is selected, and a rule requiring 25 screws no matter what drawer type is selected.
· Labor Requirement rules generate labor requirements consistent with the routing of the product and the sales options selected. In the example, we create a rule to say that the assembly time of the luxury model is seven hours more than the standard model. The user may also decide to use the standard routing for the product instead. Again, we do not create any labor requirement rules based on such options as the desk size, color, or microcomputer table. In our example, we did not create labor requirements for the drawer.
Using the Manufacturing Rules File Maintenance conversation, we defined a component requirement for each desk model (bookshelf for London and disk file for Stockholm) and a component requirement for the luxury option. The Component Requirement rules for each option are as follows (see The Manufacturing Rule Maintenance Component Requirement Detail Screen in the Manufacturing Rules section for an example of the bookshelf):
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Condition:
(O-LONDON,EQ,"Y")
Part Number:
"BOOKSHELF"
Quantity Per
1
|
If the London model is chosen
Then one bookshelf is required.
The number of components needed.
|
|
Condition:
(O-STOCKHOLM,EQ,"Y")
Part Number:
"DISKFILE"
Quantity Per
1
|
If the Stockholm model is chosen
Then one diskfile is required.
The number of components needed.
|
|
Condition:
(O-LUXURY,EQ,"Y")
Part Number:
"ROLLTOP"
Quantity Per
1
|
If the luxury option is chosen
Then one roll top is required.
The number of components needed.
|
WILLIAMS PLT BEL EXPERT CONFIGURATOR 3/03/92
DSP01 MANUFACTURING RULE MAINTENANCE DETAIL
COMPONENT REQUIREMENT
Rule Number 00120 01 Part Number DESK-100 Action Code CR Vers 01
Condition
(O-LONDON,EQ,"Y")
USAGE/SCRAP/PART NUMBER
100"BOOKSHELF"
QUANTITY PER
1
F2=Command F3=Exit F7=Header F9=Inquiry
F10=Function Select F15=Rekey Data
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The Manufacturing Rule Maintenance Component Requirement Detail Screen.
In the previous figure, the part number for the required component is preceded by two other fields, the usage code and the scrap factor. A component in a bill of material may either be used or produced (like a by-product) during the manufacturing process of the parent item. The usage code defaults to C, indicating that the component is used during the process. If the Component Requirement Rule is defined for a configured component, the usage code must be C. If not, the configurator will treat the component as if it had a usage code of C. The scrap factor represents the amount of the component which will become scrap during the manufacturing process of the parent item. The scrap factor is figured into the component requirement.
The Component Requirement rules for the drawer are defined in a similar manner.
Labor requirements were also defined in the Manufacturing Rules File Maintenance conversation for our desk example. We set up two operations (operation 0100000 assembles the basic desk while operation 0200000 assembles the roll top for the luxury model), and assigned a piece rate for each option with labor requirement rules. We also defined a standard piece rate which all desks possess. The labor requirement rules for each option are as follows (see the figure below for an example of the London model):
|
Condition:
Oper No/Ln No/Comment No
"0100000"
Piece Rate
20
|
No condition, this is the standard labor requirement for all desks.
Operation (0100000) will perform the assembly of this component.
The base length of time required to assemble this component. (20 hours)
|
|
Condition:
(O-LONDON,EQ,"Y")
Oper No/Ln No/Comment No
"0100000"
Piece Rate
25
|
If the London model was chosen.
Operation 0100000 will perform the assembly of this component.
The additional length of time required to assemble this component (added to base time). (25 hours)
|
|
Condition:
(O-STOCKHOLM,EQ,"Y")
Oper No/Ln No/Comment No
"0100000"
Piece Rate
25
|
If the Stockholm model was chosen.
Operation 0100000 will perform the assembly of this component.
The additional length of time required to assemble this component (added to base time). (25 hours)
|
|
Condition:
((O-LUXURY,EQ,"Y"),&,
(O-LONDON,EQ,"Y")
Oper No/Ln No/Comment No
"0200000"
Piece Rate
7
|
If the Luxury model and the London model were chosen, seven additional hours are needed.
Operation 0200000 will perform the assembly of this component.
The additional length of time required to assemble this component (added to base time). (7 hours)
|
|
Condition:
((O-LUXURY,EQ,"Y"),&,
(O-STOCKHOLM,EQ,"Y")
Oper No/Ln No/Comment No
"0200000"
Piece Rate
7
|
If the Luxury model and the Stockholm model were chosen, seven additional hours are needed.
Operation 0200000 will perform the assembly of this component.
The additional length of time required to assemble this component (added to base time). (7 hours)
|
|
WILLIAMS PLT BEL EXPERT CONFIGURATOR 3/03/92
DSP01 MANUFACTURING RULE MAINTENANCE DETAIL
LABOR REQUIREMENT
Rule Number 00125 01 Part Number DESK-100 Action Code LR Vers 01
Condition
(O-LONDON,EQ,"Y")
OPER NO/LN NO/COMMENT NO
"0100000"
PIECE RATE
25
F2=Command F3=Exit F7=Header F9=Inquiry
F10=Function Select F15=Rekey Data
|
The London Model Desk.
Labor Requirement rules for the drawer would be created in a similar manner. In our example, we assume that the drawer labor requirements are accounted for in the desk labor requirements.