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Lead Time Generation Report Writer - Purpose >
Lead Time Generation Report Writer - Calculations
Lead Time Generation Report Writer - Calculations
ME140E
A. Housekeeping
1. Work fields are initialized.
2. The System Control file (CT100M) is read to retrieve the company name record (COMNAM).
3. The Date Format (category 049) is retrieved from the Reference file.
4. The first transaction is read. If no transaction is found, an error message is printed and the program terminates.
B. Mainline
1. Transactions are processed in the Lead Time Generation Request file (ME140AL) until end of file is reached. If the transaction is valid, the program proceeds with lead time calculation processing. A transaction may be for all parts in a particular plant, only fixed lead time parts in a plant, only variable lead time parts in a plant, or a single part. Lead times are calculated only for active, MRP manufactured parts. JIT parts are skipped.
2. If a part is valid, its routings are retrieved from the Routing file (ME120M). If a part has no routings in the specified plant, an error message is written to the Lead Time Generation Exception report.
3. The routings are validated. A valid routing must be a primary operation, cannot be a master operation, and cannot have miscellaneous cost. The effectivity dates of the operation are checked against the effectivity date requested. If the operation is not effective on the requested effectivity date, its lead time is not calculated.
4. Because of overlapping operations, the calculations for the previous operation can depend on the current operation. The calculations for the previous scheduled operation are not terminated before the dependence on the current operation is validated.
5. There are eight types of operations:
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1.
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Standard
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2.
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Master
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3.
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Setup only overlap
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4.
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Run time overlap
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5.
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Setup and run time overlap
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6.
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Fixed time no overlap
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7.
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Fixed time setup only overlap
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Blank.
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Outside processed operation
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For every scheduled operation which is not processed outside, the operation's workcenter is retrieved from the Workcenter Master file (ME100M). Move days and queue days are calculated, giving transit days. The time between two operations within the same workcenter is called queue time. If the operations are at different workcenters, the time between operations is called move time. Setup days are calculated for operation types 1, 5, and 6.
6. Calculation of run days is based on the operation type. The piece rate is inverted if the piece rate standard is pieces/hours for operation types 1, 3, 4, or 5. Calculation is dependent on the crew flag and machine/labor paced flag:
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CREW OPERATION FLAG
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=
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Y
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PIECE RATE
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divided by
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HOURS PER DAY
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=
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RUN DAYS
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CREW OPERATION FLAG
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=
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N, MACHINE PACED
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HOURS PER DAY
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times
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NUMBER OF MACHINES
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=
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MACHINE REQUIREMENT FACTOR
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PIECE RATE
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divided by
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MACHINE REQUIREMENT FACTOR
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=
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RUN DAYS
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CREW OPERATION FLAG
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=
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N, LABOR PACED
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HOURS PER DAY
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times
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NUMBER OF PERSONS REQUIRED FOR THE
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=
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LABOR REQUIREMENT FACTOR OPERATION
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PIECE RATE
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divided by
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LABOR REQUIREMENT FACTOR
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=
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RUN DAYS
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If the operation is a fixed type and the sensitivity flag is equal to yes, run time is calculated by the following:
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PIECE RATE
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times
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(AVG ORD QTY minus (SENSITIVITY FACTOR times BATCH QTY))
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BATCH QTY
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HOURS PER DAY
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7. If the previous operation type is 1, 3, 4, or 5 and the current operation is 4 or 5, and if the average order quantity is less than the overlap quantity/overlap percent defined for the operation, the overlap quantity/percent is used in the calculation of run days instead of the average order quantity.
8. For a variable lead time part, the minimum quantity is set at the same time that run days are recalculated for overlapped operations.
9. Setup days, transit days, fixed days, and run days are printed for variable lead time parts. For fixed lead time parts, setup days, transit days, fixed days, and total lead time days are printed.
10. If updating of the Part Master (DE100M) is requested, the total fields replace corresponding fields in the Part Master. In case of overflow, no updating is done.