Labor Requirements Inquiry - Calculations

A.   Housekeeping

1.   All work fields are defined and initialized.

2.   The following information is retrieved from the System Control file (CT100M):

a.   The company name record (COMNAM) is retrieved and formatted for output on the System Error report (CT010X).  If the record is not found, a message is sent to the system operator and processing continues.

3.   The following information is retrieved from the Reference file (REFERP):

a.   The date format (category 049) is retrieved.  If this record is not found, a message is sent to the system operator, the date format defaults to MMDDYY, and processing continues.

b.   The user authorization (category 409) is retrieved to determine which plants the user is authorized to.

c.   The workstation assignment (category 428) is retrieved for the default plant.

d.   The order policy codes and descriptions record is retrieved and the codes and descriptions are moved to an array.  The array is used to match the Order Policy Code on the Part Master Record to its description.  If the record is not found, a message is sent to the system operator and the program aborts.

4.   The Warehouse Description file (IC170M) is used to validate the plant displayed on the screen.  It is also used to retrieve the Piece Rate Standard (WDPRAT) and Operation-to-Operation Reconciliation Factor (WDOPOP).

5.   The program Status field (PGMSTS) is set to direct screen processing.

a.   If the program was entered from the Labor Requirements Maintenance (SF100E), Labor Requirements Update (SF120E) or Manufacturing Order Status Inquiry (IC830E) programs, the Fast Path Item field (FPITEM) contains the Order Number for the inquiry.  This Order Number is validated against the Manufacturing Order file (IC100ML1).  If it is valid, the Program Status Code is set to LAB; the program bypasses the select screen and goes directly to the Operation Status Screen.  If the Order Number passed is invalid, the Program Status is set to PMT; the select screen is displayed with the appropriate error message.

b.   In all other cases, the Program Status is set to PMT, and the select screen is displayed.

6.   Fast path parameters are accepted from the Capacity Planning Load Detail Inquiry program (CP810E).

B.   Function Select

1.   The select screen is displayed; the user enters an Order Number as the part for inquiry.  The Request Code is entered for the type of inquiry desired:  labor requirements details for the order (RCODE = 1); efficiency details for the order (RCODE = 2); or reconciliation details for the order (RCODE = 3).

2.   The select screen is validated; any errors that occur are displayed on the select screen.  If screen entries are valid, program status is set for the requested detail screen.

C.   Operation Status

1.   This screen displays labor requirements records for the requested order.

If the manufacturing order is for a configured part, the sales order line is retrieved and an indicator is turned on to display the field.

2.   The manufacturing order descriptive information is retrieved from the logical Manufacturing Order file (IC100ML1).  The following formatting and calculations are performed for the section of the screen that provides the order information:

a.   All dates are formatted for display.

b.   The Filter Quantity (ORFLQY) is calculated by dividing the Reconciliation Filter (OORFSF) by 100, and multiplying the result by the Order Quantity (HORDQ).  This amount is saved for later processing.

c.   The Actual Scrap Rate (CSCRT) is calculated by dividing the Cumulative Scrap (HSCRAP) by the Order Quantity (HORDQ) and then multiplying the result by 100.

d.   The Order Type Description field is retrieved from the internal order codes and descriptions array.

e.   The subfile, which will hold the individual labor requirements records for the order, is cleared.

3.   The individual records are formatted for display, and calculations are performed as follows:

a.   The labor requirements records for the requested order are retrieved to build the subfile display.  If no labor requirement records exist, an error message is displayed on the select screen.

b.   The dates for each record are formatted for display on the subfile line.

c.   The Quantity Complete from the first operation is saved.  This field (SVQTCP) is incremented after the Reconciliation Error has been calculated for each operation.

d.   The Reconciliation Error is calculated by subtracting the Quantity Complete for the previous operation (SVQTCP) from the sum of the Quantity Complete (LRQTCP) and Quantity Scrapped (LRQTSP) for the present operation.  If the Reconciliation Error is greater than the calculated Filter Quantity (ORFLQY) a warning message is written to the detail screen; the operation in error is highlighted.

e.   Each record is formatted prior to being written to the display subfile.

4.   Return to the select screen is executed by pressing the ENTER key.

5.   Command key entry into Manufacturing Order Status Inquiry program (IC830E) is supported via F11; entry into the Labor Requirements Maintenance program (SF100E) is supported via F9.  When either F9 or F11 is entered from this screen, the Order Number being processed is passed to the requested program.

6.   The user may request more detailed information for a particular operation by operation by entering an X in the Inquiry Select Flag field to the right of each line and pressing the ENTER key.  Control is passed to the Operation Detail Screen.

D.   Efficiency

1.   This screen provides information about the efficiency of the labor and machine-paced operations for the requested manufacturing order.

2.   The Order Number and Part Number are retrieved from the logical Manufacturing Order file (IC100ML1) for heading information.  The order description is retrieved for display in the efficiency subfile.  The subfile, which will hold the individual records, is cleared.

3.   The labor requirements records for the requested order are retrieved to build the subfile display.  If no labor requirements records exist, an error is displayed on the select screen.

4.   If the operation is neither fixed time nor outside processed, the following calculations are performed:

a.   For a labor-paced operation, Labor Hours Earned and Labor Efficiency are calculated as follows:

Labor Hrs Earned*  =  Quantity Complete times Piece Rate (hours per piece)

or

* For a crew operation, the result is then multiplied by the Number of Persons.

b.   For a machine-paced operation, Machine Hours Earned and Machine Efficiency are calculated as follows:

or

c.   The Manning Variance (MANVAR) is calculated.  If Labor Hours Reported (LRLHRP) equals zero and Number of Persons (LRNOPR) equals zero, then Manning Variance is set to zero.  If Labor Hours reported is not equal to zero then Manning Variance is calculated thus:

d.   If an overflow occurs in any of the above calculations, the affected field is set to all nines.

5.   Each record is formatted prior to being written to the display file.  If the operation is fixed time or outside processed, the calculated fields just described are left blank.

6.   Return to the select screen is executed by pressing the ENTER key.

7.   Command key entry into the Manufacturing Order Status Inquiry program (IC830E) is supported via F11; entry into the Labor Requirements Maintenance program (SF100E) is supported via F9.  When either F9 or F11 is entered from this screen, the Order Number being processed will be passed to the requested program.

8.   The user may request more detailed information for a particular operation by entering an X in the Inquiry Select Flag field to the right of each line and pressing the ENTER key.  Control is passed to the Operation Detail Screen.

E.   Reconciliation

1.   This screen gives details of reconciliation between totals of operations for a requested order.

2.   The descriptive information for the specified order is retrieved from the logical Manufacturing Order file (IC100ML1).

a.   All dates are formatted for display.

b.   The order type descriptive field is retrieved from the internal order codes and description array.

c.   The subfile, which will hold the individual records, is cleared.

3.   The labor requirements records for the requested order are retrieved to build the subfile display.  If no labor requirements records exist for each operation (after the first), an error message is displayed on the select screen.

4.   The Operation-to-Operation Reconciliation Quantity (OPTOP) is calculated for each operation (after the first) by subtracting the sum of Quantity Complete (LRQTCP) and Quantity Scrapped (LRQTSP) for the present operation from the Quantity Complete of the previous operation (SVQTCP).

5.   The Operation-to-Order Reconciliation Quantity (OPTOR) is calculated for each operation by subtracting the sum of Quantity Complete (LRQTCP) and Quantity Scrapped (LRQTSP) for the present operation, from the Order Quantity (HORDQ) minus the Cumulative Scrap (LRCMSP) for the order.

6.   Each record is formatted prior to being written to the display file.

7.   Return to the select screen is executed by pressing the ENTER key.

8.   Command key entry into the Manufacturing Order Status Inquiry program (IC830E) is supported via F11; entry into the Labor Requirements Maintenance program (SF100E) is supported via F9. When either F9 or F11 is entered from this screen, the Order Number being processed is passed to the requested program.

9.   The user may request more detailed information for a particular operation by entering an X in the Inquiry Select Flag field to the right of each line and pressing the ENTER key.  Control is passed to the Operation Detail Screen.

F.   Operation Detail

1.   The Operation Detail Screen may be requested from any of the other operation displays within the program, but not from the select screen.  This screen is selected by entering an X to the right of the desired operation and pressing the ENTER key.  If no X is entered and the ENTER key is pressed, control returns to the select screen.

2.   The screen displays data from the logical Labor Requirements file for the requested operation.  The Machine or Labor Hours Earned and the Machine or Labor Efficiency are calculated exactly as they are for the Efficiency Screen.  Refer to that section for more details.

3.   Command keys are available to move sequentially (forwards or backwards) through the logical Labor Requirements file (IC125ML2) for the given Order Number.  F10 allows the entry of a new Order Number.  The ENTER key returns the user to the previous screen.

4.         Command key entry into the Labor Requirements Maintenance program (SF100E) is supported via F9; the Order Number being processed is passed to the program.  It is not possible to enter the Manufacturing Order Status Inquiry program (IC830E) from this screen.

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