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Manufacturing Order Maintenance - Calculations
Manufacturing Order Maintenance - Calculations
IC100E
A. Housekeeping
1. See Common Processing Routines - Housekeeping in this manual for a general discussion of this subroutine. Processing specific to this program is described below.
2. The following information is retrieved from the System Control file (CT100M). If any of the records are not available, defaults are used, a message is sent to the system operator, and processing continues.
a. The company name is retrieved from the company name record (COMNAM).
b. If the Shop Floor Control application is installed, the SFCTL1 record is checked for the average hours per day (AVHRPD).
3. The following information is retrieved from the Reference file (REFERP).
a. The applications installed record (category 012) is retrieved and saved. If not found, a message is sent to the operator and processing continues.
b. The date format record (category 049) is retrieved. If this record is not found, the date format defaults to MM/DD/YY and processing continues.
c. The decimal field precision record (category 446) is retrieved to determine the default number of decimal positions for order quantity fields. If this record is not found, a message is sent to the system operator and the program aborts.
d. If the Inventory Accounting module has been installed (determined in Step 3.a., above), the accounting grace period record (category 456) is retrieved. If this record is not found, the grace period defaults to zero (i.e., there is no grace period) and processing continues.
e. Reference File category 409 is read to determine which plants the user is authorized to use.
f. Reference File category 428 is read for the default plant.
g. Reference File category N37 is read to determine the message queue assignment for the manufacturing monitor (monitors).
4. Overflow fields are set for maximum values determined by the quality field sizes retrieved above.
B. Mainline
1. On the Manufacturing Order Maintenance Function Select screen (IC100S01) the part number, the display components field, and the maintenance code are validated. (See the Inventory Control User Manual for validation rules.) The user may also invoke F17 to change the plant, and F24 to change the transaction date.
2. The data entered on the Function Select screen determines which elements of the detail screen are displayed next (refer to the screen sample below).
a. If the specified maintenance code is 2 through 7 (change, release, firm, cancel, close, or reopen), the Part Number field must be blank.
(1) If a valid order number is entered, the full Manufacturing Order Maintenance Detail screen is displayed.
WILLIAMS PLT BEL INVENTORY CONTROL 4/11/95
DSP01 MANUFACTURING ORDER MAINTENANCE ADDITION
Order Part Number/ O O S S V Order Start Due Pln Gn
Number Description T S P O O Quantity UM Date Date Cde LR H
0000001 CAR M F B 1 1 1.000 EA 041195 041195 A Y N
CONFIGURED CAR
Cfg Cde
Lin Component C Quantity Quantity Scrap Off U Required I Oper
No Part Number S Issued Per Factr Set C Quantity UM C No
01 INTERIOR O .000 1. .00 000 C 1.000 EA R
Seq 000
02 BODY O .000 1. .00 000 C 1.000 EA S
Seq 000
03 TIRES O .000 4. .00 000 C 4.000 EA R
Seq 000
04 GLASS O .000 1. .00 000 C 1.000 EA R
Seq 000
05 ENGINE O .000 1. .00 000 C 1.000 BX R
Seq 000
F2=Command F3=Exit F4=Prompt F6=Fold/Truncate
F9=Inquiry F10=Function Select F12=Comments F24=More Keys
|
Elements of the Manufacturing Order Maintenance Detail screen
(2) If no order number is entered, the detail screen is displayed.
(3) If an invalid order number is entered, the detail screen is displayed with an error message.
b. If the specified maintenance code is 1 (addition), both a valid order number and a valid part number are required.
(1) If a valid order number and valid part number are entered, the detail header screen is displayed.
(2) If only a valid order number or valid part number is entered, the detail screen is displayed.
(3) If an invalid order number and/or invalid part number is entered, the detail screen is displayed with an error message.
3. If there are no errors, an application locking record for the order number is written to the Component Requirements Asynchronous Transaction file (IC100AP2). This record contains the screen order number and a component part number and usage code of all nines. It allows only one user to update the record at any time. (Refer to the Technical Support Manual for information on application locks.) The Manufacturing Order Generation program (IC102E) processes the order and then deletes the application locking record.
4. The Manufacturing Order Maintenance Detail screen (IC100S02) is displayed. The manufacturing order maintenance functions are described below. If the user requested the display of components on the Function Select screen, component requirement maintenance (see step 6) can also be performed.
If the manufacturing order is for a configured part, the original sales order line, if any, is retrieved and an indicator is turned on to display the field.
In a job-controlled environment, an M.O. can be associated with a job if the M.O. is for a job-controlled part. The job associated with an M.O. cannot be closed or accounting closed (status of or ). If the M.O. is for a non job-controlled part, the M.O. cannot be associated with a job (for options 2-7, job number is display only).
5. Manufacturing Order Maintenance
The business conversation for each manufacturing order maintenance function is described up to its confirmation status. (When the conversation is complete, the screen is protected from input, and a warning message is displayed.)
Add, change, release, and firm transactions may also include component requirement maintenance, if desired. The processing of these transactions continues with step 7.
No component requirement maintenance is permitted for cancel, close or reopen transactions. The processing of these transactions continues with step 8.
a. Add an Open or Firm Order
The order header line is displayed. Order type and status, production type, shop paperwork option, order quantity, start and due dates, order description, and configuration code (if the Expert Configurator is installed and the part is configuration coded) are validated. (See the Inventory Control User Manual for validation rules.) Buyer or analyst code, part description, and unit of measure values are retrieved from the Part Master file (DE100M). The shop paperwork value displayed is the default value (WDSPDO) retrieved from the Warehouse Description File during Plant Validation. If Shop Floor Control is installed, the Generate LR option is displayed with a default value of 'Y.' If no order quantity is entered, the program uses the batch quantity specified on the part master record. The order type and status cannot be changed once they have been posted.
If only one date is entered (either start date or due date), the other date is calculated. If the due date has not been entered and the Leadtime Code (AMLTC) is equal to "V" (variable), the due date is calculated by multiplying the order quantity (HORDQ) by the total run hours per piece (MLTRH). The total setup days (MLTSU) and total transit days (MLTQM) are added to the result. The result is then added to the start shop date giving the new due shop date. If the Leadtime Code is equal to "F" (fixed), then the total leadtime days (MLTPM) is added to the start shop date giving the new due shop date. The calendar due date is then retrieved from the shop calendar file. If the start date has not been entered, then the same processing is followed but the totals are subtracted from the due date to give the new start date.
If the display components option was requested on the Function Select screen, the detail screen is locked after the manufacturing order header data is entered, a warning message is displayed, and the Component Requirement Creation program (IC104E) is called. This program returns a code (CRGEN) to Manufacturing Order Maintenance.
(1) If CRGEN equals "EXCPTN," an exception condition has occurred in component requirement creation. The Manufacturing Order Maintenance program deletes the application locking record for this order and ends the program.
(2) If CRGEN equals "OVERFL," an overflow condition on the order quantity exists. The Manufacturing Order Maintenance program displays the error message and allows the user to enter data in the maintainable order header fields.
(3) If CRGEN equals "NOCOMP," there are no effective components for the order. The Manufacturing Order Maintenance program displays the component requirements subfile field headings, the component requirements maintenance select, and a warning message to allow the addition of component requirements. If none are added, a critical error occurs.
(4) If CRGEN equals "EXPLOD," there are active components. However, the components on the order are not true components (i.e., reference parts). A manufacturing order for the parent part must have true components. The Manufacturing Order Maintenance program displays the component requirement subfile field headings, the component requirements maintenance select, and a warning message to allow the addition of component requirements. If no true components are added, a critical error occurs.
(5) If CRGEN equals "END---," the generation of component requirements was successful. The Manufacturing Order Maintenance program displays the component requirements maintenance select and the component requirements subfile, which is loaded from the Component Requirements Asynchronous Transaction file (IC100AP2).
If a rework order (order type is ) is added and the display components option was requested on the Function Select screen, the component requirements subfile headings and component requirements maintenance select are displayed for the user to add component requirements to the order. However, it is not an error if the order has no components.
If the display components option was not requested, only order header line maintenance is allowed for both manufacturing and rework orders. The Manufacturing Order Maintenance Generation program will asynchronously generate the component requirements for manufacturing orders.
b. Change an Open or Firm Order
Order header line maintenance, excluding order type status, is allowed. (See the Inventory Control User Manual for validation rules.) If the order quantity is changed and the component requirements subfile is displayed, the Required Quantity field on all subfile records is calculated (see Required Quantity calculations below) and updated. The Generate LR Option is displayed with a default value of , unless the order already has LR. The user must make at least one change to either the order header or component requirements subfile. Otherwise, a critical error occurs.
Requisition Parts
Required Quantity = (Quantity Per times Order Quantity) divided by
(1 minus Calculated Scrap Factor)
Simultaneous Issue and Receipt Parts
Required Quantity = [(Order Quantity minus Quantity Received)
times Quantity Per] divided by (1 minus Calculated Scrap Factor) plus Quantity Issued
where:
Calculated Scrap Factor = Scrap Factor divided by 100.
c. Release a Firm or Planned Order
The Order Status screen field is changed to "O" (open) by the program and displayed. Order header line maintenance, excluding order type and status, is allowed. (See the Inventory Control User Manual for validation rules.) The order number may be changed when a planned order is released. The Generate LR Option is displayed with a default of unless the order already has LR. If the order quantity is changed and the component requirements subfile is displayed, the Required Quantity field on all subfile records is calculated (see Required Quantity calculations above) and updated.
d. Firm a Planned Order
The Order Status screen field is changed to "F" (firm) by the program and displayed. Order header line maintenance, excluding order type and status, is allowed. (See the Inventory Control User Manual and the Purchasing User Manual for validation rules.) The order number may be changed. The Generate LR Option is displayed with a default value of 'Y.' If the order quantity is changed and the component requirements subfile is displayed, the Required Quantity field on all subfile records is calculated (see Required Quantity calculations above) and updated.
e. Cancel a Firm Order
No order header line maintenance or component requirement maintenance is permitted. The Order Status screen field is changed to "X" (canceled) by the program. If the component requirement subfile is displayed, the component status code on all subfile records is also changed to an "X" (canceled). The detail screen is set in confirmation status and the PRESS ENTER/REC ADV TO PROCESS message displayed.
f. Close an Open Order
The Order Status screen field is changed to "C" (closed) by the program and displayed. No order header line maintenance or component requirement maintenance is permitted. If the component requirements subfile is displayed, the component status code on all subfile records is also changed to "C" (closed). If none of a particular component have been issued, the Quantity Issued Field is highlighted and a warning message is written to the error subfile. A warning message is also written if the quantity received on the order is not the same as the order quantity. The warning message is also displayed on the next screen to be displayed. The detail screen is set in confirmation status and the PRESS ENTER/REC ADV TO PROCESS message displayed.
g. Reopen a Closed Order
No order header line maintenance or component requirement maintenance is permitted. The order status is changed to "O" (open) by the program. If the component requirements subfile is displayed, the Component Status Code on all subfile records is also changed to "O" (open). The detail screen is set in confirmation status and the PRESS ENTER/REC ADV TO PROCESS message displayed.
6. Component Requirement Maintenance
Component requirement maintenance is permitted when the manufacturing order is being added, changed, released, or firmed. The user must enter a subfile line number (not required for addition of a record) and a maintenance code on the component requirement maintenance select (see Manufacturing Order Maintenance Detail screen sample above) to effect maintenance on a component requirements record. The maintenance codes are:
- Add a Component Requirement
- Change a Component Requirement
- Cancel a Component Requirement
- Reinstate a Component Requirement
a. Add a Component Requirement
A blank component requirements maintenance line is displayed for entry and validation of component part number, quantity per, required quantity, issue code, operation number, and configuration code for configured components. (See the Inventory Control User Manual for validation rules.) The part status of the component must be valid for the bill of material, as defined on Reference File category D88. The Unit of Measure and Issue Code for the part are retrieved from the Part Master file.
The required quantity for the part is calculated based on Issue Code. If the Issue Code is 'R', the Required Quantity is calculated by the program. If the Issue Code is 'S' or 'T', the user may specify the Required Quantity or, if the field is left blank, the program calculates it. Please refer to the Required Quantity calculations above.
If valid, the component requirement line is added to the end of the component requirement subfile and a record (order number, component part number) is written to Component Requirement Asynchronous Transaction file. The subfile record is flagged as an addition.
b. Change a Component Requirement
The requested subfile record is displayed on the component requirement maintenance line with the Component Part Number field protected from user input. Validated fields include Quantity Per, Required Quantity, Issue Code, Operation Number, and configuration code. (See the Inventory Control User Manual for validation rules.) Please refer to the Required Quantity calculations above.
If the changes are valid, the component requirement subfile record is flagged as changed and updated with the changes.
c. Cancel a Component Requirement
The requested subfile record is displayed on the component requirement maintenance line with all fields protected. Once the key is pressed, the component requirement subfile record is flagged as changed and the Component Status Code is updated to an "X."
d. Reinstate a Component Requirement
The requested subfile record is displayed on the component requirement maintenance line with Component Part Number field protected from user-input. Validated fields include Quantity per, Required quantity, Issue Code, Operation Number, and configuration code. (See the Inventory Control User Manual for validation rules.) See Required Quantity calculations above for the required quantity calculation. If the changes are valid, the component requirement subfile record is flagged as changed and the Component Status Code is updated, changing from an "X" to an "R."
7. If the order maintenance class is not cancel, close, or reopen, the maintenance conversation is considered complete when no errors exist for the order header and the component requirements maintenance line selects are blank (if display components requested). The screen changes to confirmation status with all order header fields protected from user input. No component requirement maintenance is allowed, and the PRESS ENTER/REC ADV TO PROCESS message is displayed. An order cannot be released unless all the required configuration codes have been entered for configuration costed parent and component parts.
8. Once the ENTER key is pressed, transaction records (T0509) are written to the Component Requirements Asynchronous Transaction file for all component requirements subfile records that have been flagged as changed. Those component requirements subfile records flagged as additions have their corresponding asynchronous transaction records updated. A manufacturing order transaction record (T0508) is written to the Manufacturing Order Asynchronous Transaction file (IC100AP1) for the order number.
9. A message containing the asynchronous maintenance type (1), the workstation ID, and the order number are sent to the asynchronous message queue which was specified on Reference File category N37 and the detail screen is returned to select status.
10. Command keys available to the user during IC100E include F9, F15, F16, and F17.
a. F9 - Enter Inquiry deletes all component requirements asynchronous transaction records and the application locking record for the order number. Transfers control to the Manufacturing Order Status Inquiry program (IC830E).
b. F15 has three variations: Rekey Order, Rekey Data, and Maintenance. Rekey Order clears the application locking record, and any added transaction records for this order number, from the Component Requirements Asynchronous Transaction file and returns the detail screen to select status. Rekey Data clears the full component requirements maintenance line fields and displays the partial maintenance line. Maintenance returns the detail screen from confirmation status to permit maintenance again.
c. F16 - User Defined fields allows you to enter specific data for your company and stores it on the Manufacturing Order file.
d. F17 - Allows the user to change the plant for the manufacturing order. The plant is checked to see if it is valid and if the user is authorized to maintain it.
11. If during maintenance, F3 - Exit or F10 - Select Function is pressed, the component requirement asynchronous transaction records for the order number and the application locking record are deleted. These records are also deleted if the user exits the program using fast path.