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Manufacturing Configurator Process - Calculations
Manufacturing Configurator Process - Calculations
EC200E
A. Housekeeping
1. Work fields are defined and program constants are initialized.
2. The following information is retrieved from the Reference file (REFERP).
a. The operating system's file access codes are retrieved from category 015. If this record is not found, the program ends abnormally.
b. The applications installed information is retrieved from category 012.
c. The system default for currency is retrieved from category 133.
d. The number of decimals for quantity fields is retrieved from category 446.
e. The current sales period is retrieved from category 407.
f. The last sales period posted is retrieved from category 435.
g. The in-use codes are retrieved from category D01.
3. An array with ten to the power of one through six is loaded to convert packed decimal fields.
4. The report request files for the Manufacturing Errors Detected report, Comments Generated report, and Change Configuration report are opened if operating in batch mode.
B. Mainline
1. If the program is operating in an asynchronous mode, the Asynchronous Transaction file (EC200DP) is read.
2. The first option line to be configured is retrieved from the Sales Order Options file and processed. If the program is operating in an asynchronous mode, only options records for the sales order retrieved from the Asynchronous Transaction file are processed.
a. The sales order header is locked.
(1) The previous sales order processed is unlocked if it was locked by Manufacturing Configuration.
(2) The current sales order header is set to be in use by Manufacturing Configuration. If another user/process is locking the sales order, the program will flag the option as being in error and produce an error report describing who/what has the sales order locked.
b. Information for the plant on the option record is retrieved.
c. The sales order line being processed is retrieved.
d. The manufactured part must be active on the Part Master file and the part status must be valid for manufacturing orders, as defined on Reference File category D88.
e. Work fields, counters, and arrays are initialized for the option being processed.
(1) Previous manufacturing errors detected, comments generated, and manufacturing trace records are deleted.
(2) Report requests for Manufacturing Errors Detected, Comments Generated, Manufacturing Trace, and Change Configuration reports are produced for the previously processed sales order line if necessary. If processing in an asynchronous mode, these report programs will be called directly from EC200E and the reports will show up as spooled files for the Manufacturing Configuration Monitor. If an error was encountered during processing, the only reports that will be produced are the Errors Detected and Manufacturing Trace. The Manufacturing Trace report will never be directly called from EC200E. In order to get this report, release the pending job for the Trace report from the Release Submitted Jobs option.
(3) The Manufacturing Order Quantity is formatted. For the part on the sales order line (option sequence number 1) the M.O. quantity will be the line order quantity. For lower level configurations, the M.O. quantity will be the quantity of the configured component for the parent multiplied by the parent's M.O. quantity (i.e., ordered quantity).
For lot assignable configured items, the Manufacturing Order (M.O.) conversation will generate an M.O. for the unreserved sales order quantity only. If you are able to find existing inventory to fill a portion of the sales order, an M.O. will be generated for the remaining inventory needed. If the order can be filled entirely from existing stock, no M.O. will be generated. This reservation only occurs for the end item.
If the configured item is lot controlled but not lot assigned, an M.O. will be generated for the full sales order quantity regardless of the inventory reserved. This allows "true lot control" because a new lot number is generated each time inventory is created.
For manufacturing orders at lower levels of the bill of material, the order quantity will be based on the order quantity of the highest level manufacturing order and the quantity per relationships between the parent and child parts. The configuration code is saved on the manufacturing order and on the component requirements for configured components. When the configured component is issued to an M.O., the lot number must match the component requirement's configuration code.
When an M.O. is completed for a configured item, you can record the receipt into inventory. At this time a lot number is assigned to the inventory and a cross-reference between the lot and the configuration code is generated in the Configuration Assignment file. You may specify a lot number or leave it blank and have one assigned. The next sequential lot number is held on Reference File category Y34.
(4) The sales order options are loaded into array's to save the parent/component relationship.
f. If a manufacturing order is going to be produced for this option record, the last configured manufacturing order (M.O.) is incremented by one and validated against the Manufacturing Order Header file (IC100ML1) to see that it does not exist.
g. The option's arrays are initialized.
h. All manufacturing rules for the part are processed.
(1) Starting with the virtual rule, the first released rule for the part is retrieved.
i. If it is a *ALL rule, the *ALL and rule version numbers are compared to the part's manufacturing rule version number.
ii. If it is a group rule, the part is checked to see if it is a member of the group, and the group and rule version numbers are compared to the part's manufacturing rule version number.
iii. If it is a subgroup rule, the part is checked to see if it is a member of the subgroup, and the subgroup and rule version rule version numbers are compared to the part's manufacturing rule version number.
iv. If it is a specific part rule, the rule version number is compared to the part's manufacturing rule version number.
(2) If a rule is found it is processed.
i. If manufacturing trace is active, the rule information is saved for the manufacturing trace report (EC520A).
ii. If the rule is a standard rule, the condition, resultant 1, and resultant 2 are processed according to the action code.
iii. If the rule is a Labor Requirements Rule and the part uses standard routing, the rule is not processed.
iv. If the rule is a Component Requirements Rule and the part uses standard bill of materials, the rule is not processed.
v. If the rule is a Comments Generated Rule, a record is written to the Comments Generated file (EC230AP).
vi. The component requirement must be an active part on the Part Master file and the part status must be valid for bill of material, as defined on Reference File category D88.
(3) The rules are retrieved recursively. First the rules released by the current rule are retrieved. When they have all been retrieved, the rules released by the parent rule of the current rule are retrieved.
(4) If standard bill of materials is used for the part, it is processed.
(5) If standard routing is used for the part, it is processed.
(6) If no errors have occurred, the files are updated.
i. The manufacturing order beginning and ending dates are determined.
ii. The transaction files (IC100AP1, IC100AP2) are updated. If the item entered on the Manufacturing Order Header is configured, update IC100AP1 with the Configuration Code. If the Components are configured update IC100AP2 with the Configuration Code.
iii. The last configured M.O. number is updated on the Reference file.
iv. If the Configuration Code does not exist on the Configuration Code file (EC140M) add it.
v. The Manufacturing Order Post program is called to create the M.O.
vi. If processing the last option record for the sales order line, the booked sales cost and cost of goods sold are updated on the Customer Master file (ARCUSTL9) and Sales Order Header and Line files (OP100M1, OP100M2) respectively. The configuration Costs are retrieved from the Configuration Cost Rollup and Generation program (EC180E). If the Costs returned are zero use the Standard Costs otherwise use the Configuration Costs.
vii. The Sales Order Options file (EC200M) is updated with the manufacturing order number.
i. If the program encountered an error, all MOs created during this run for the Sales Order Options records are deleted and the Sales Order Options are set to have a process code of 'E'.
j. If the program status is in error, then the Errors Detected record is written (EC220AP).
3. Trigger records are written to the report request files for the Manufacturing Errors Detected, Manufacturing Trace, Comments Generated, and Change Configuration reports if necessary.
4. If the sales order header is still locked from detail processing, it is unlocked.
5. The Manufacturing Order Post program is called to close open files.
6. Final changes to the data base are committed.
7. If processing is in asynchronous mode, an error message is sent to the last maintenance workstation for the Sales Order Header if it is not an Order Processing program name.
8. If processing is in asynchronous mode, the next asynchronous transaction record is retrieved and processing continues until there are no more asynchronous transactions found.
9. If processing in a batch mode, the report request files are closed.