Labor Requirements Maintenance - Calculations

SF100E

A. Housekeeping

1. Work fields are defined; program constants are initialized.

2. Data is retrieved from the System Control file (CT100M):

a. The company name is taken from the company name record (COMNAM). If it is not found, a message is sent to the system operator, a message is moved to the company name print field, and processing continues.

b. The system post options are taken from the Shop Floor Control Record (SFCTL1). If any of these are not found, the program aborts.

3. Data is retrieved from the Reference file (REFERP).

a. The date format is retrieved from category 049. 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 company/warehouse combinations for which the user is authorized are obtained from category 409. A flag (ALLCW) monitors if the user is authorized to all company/warehouses or not.

c. The workstation default values for co/whs and plant are obtained from category 428. The default plant is validated.

d. The quantity field size for order quantities is obtained from category 446. If it is not found, a message is sent to the system operator and the program aborts.

e. Reference File category N37 is read to determine the message queue assignment for the manufacturing monitor (monitors).

4. If the system post option for comments contains N, the function select screen is set so that the comment maintenance option is not displayed.

5. If the program has been called via fast path or command key, the Order Number field is retrieved for display, and the plant field is retrieved for validation.

6. The System Date and User Reference-ID are formatted as screen defaults.

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

B. Mainline

1. Control is passed between the full function select screen, the partial screen, and the maintenance detail screen.

C. Function Select

1. The Labor Requirements Maintenance Function Select Screen is displayed. The plant specified by the user is validated. Command keys are available for exit, fast path, and transfer to the Labor Requirements Inquiry program (SF810E). A new transaction date may also be entered via command key. A new plant may be entered via a command key.

2. The processing request that is entered by the user is validated. See the Shop Floor Control User Manual screen section for validation rules.

a. If the three display options and the Maintenance Code are all valid, the Order Number is validated against the Manufacturing Order file. The plant specified on the screen must be the same as the plant for the M.O.

b. If the Order Number is not valid, the partial function select screen is displayed, along with the current program function (GENERATE or MAINTAIN). Command keys are available for exit, fast path, transfer to the inquiry program, and return to the full function select screen. An order number is the only valid entry to this screen; it is validated against the Manufacturing Order file.

c. If the Order Number is valid, and if the order start and due dates are on the Calendar Date file, an application locking record is written to the Component Requirements ASYNC Transaction file (IC100AP2); delimiter records are written to the Labor Requirements ASYNC Transaction file (IC100AP3). The System Date and Time are retrieved for use in sequencing the records in the Transaction Register.

3. Either the logic to Generate Labor Requirements or the logic to Maintain Labor Requirements is performed, depending on the user request.

D. Generate Labor Requirements

1. Labor requirements records are generated from the operations listed on the Routing file for the parent part on the order. Only operations that are effective as of the start date of the order are converted into labor requirements. All routing steps which have neither a piece rate nor a lead time (except comments and master operations) are ignored. JIT operations are ignored.

2. The inclusion of comments and alternates in the Labor Requirements file is determined by the system wide options to support comments and inactive operations (alternates). The display of comments and alternates is determined by the values entered on the function select screen.

3. As each operation record is read, data is transferred from the routing record to the corresponding new labor requirement record. This includes piece rate, setup hours, number of persons and machines required, permissible run time overlap (with the preceding operation), and descriptive data (tool and machine number).

4. The Workcenter file is accessed for the workcenter that will perform each operation. The working hours per day, move and queue times, and machine- or labor-paced flag are transferred to each labor requirement record.

5. Each primary routing operation is scheduled sequentially (backwards or forwards) before being written to a program workfile as an active labor requirement. Alternate operations (if selected) and comments (if selected) are written directly to the work file as inactive labor requirements. Alternate operations for master operations are invalid and are rejected.

6. Master operations are validated before being written to the workfile. A master is only valid when it is preceded in the routing by active operations in a given workcenter that all have identical crew flags. Consecutive master operations, and master operations separated only by inactive labor requirements or comments, are also invalid. For backward-scheduled orders only, the part master record for the ordered part is locked during this validation to prevent intervening routing maintenance.

7. Each active labor requirement that is associated with a given master operation is updated with a pointer to that master operation. This is for use in later validation.

8. Once all the operations for the ordered part have been read and loaded into the workfile, they are displayed on the screen. Control is passed to the maintenance detail screen.

9. If no labor requirements records were generated from the Routing file, a warning message is displayed and new labor requirements may be added. If a display of the generated labor requirements was not requested on the function select screen, requirements will be generated and posted asynchronously by the Manufacturing Order Generation program (IC102E).

E. Maintain Labor Requirements

1. Labor requirements maintenance occurs when existing labor requirements are altered. If a manufacturing order is a rework order and the HLRS flag (indicating whether or not any labor requirements have been generated) is set to N, you can enter the Labor Requirements Maintenance conversation and select option 2 for maintaining labor requirements. The program should display a blank Labor Requirements subfile where desired labor requirements can then be entered. Once at least one labor requirement has been entered, the HLRS flag will be updated to Y.

2. New requirements are added individually via the detail screen. They are eventually posted from the workfile to the Labor Requirements file. This processing is discussed in the following section.

3. If existing labor requirements are being maintained, any outstanding rescheduling is performed before the requirements are loaded into the workfile and displayed. Records are read and displayed according to the options specified on the function select screen; comments and inactive operations may be ignored.

4. Control is passed to the maintenance detail screen.

F. Maintenance Detail

1. The detail screen, consisting of the order header and its labor requirements records, is displayed. Command keys are available for: exit; fast path; transfer to the inquiry program; selecting a function or another order (without posting the current labor requirements); and updating the order header start and due dates to correspond with the scheduled labor requirement start and due dates (at time of posting).

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. Once the program workfile has been loaded (through either the generate or maintain processing), a workline is provided at the foot of the screen. This workline may be used to add or maintain individual records. The user enters a maintenance code and sequence number (if required), and these are validated. See the Shop Floor Control User Manual for validation rules.

3. If an existing record is being maintained, an appropriately formatted copy of that record is displayed in the workline. Processing continues based on the user-specified maintenance code:

O	Add a new operation
M	Add a new master operation
C	Add a new comment line
U	Update an existing labor requirement
D	Delete an existing labor requirement
A	Activate one or all of the existing inactive operations (alternates)
P	Page to display a particular line

a. Add a new operation.

Operations may be added to the labor requirements on the order at any workcenter that is on the plant for which the order is issued. Additions are not permitted to separate masters from their detail operations once machine or labor activity has been reported; but if no activity has occurred, then any existing master operation will automatically become associated with an added operation if appropriate.

Workcenter data is retrieved from the Workcenter file and transferred to the new labor requirements record. Data on piece rate at the operation, setup hours, and the number of persons and machines must be entered to the screen. Extensive validation of the data entered is performed, including checking for potential overflow conditions; each addition is also validated against master operations to ensure integrity in labor and crew performance reporting. See the Shop Floor Control User Manual for further validation rules.

Each valid new operation will be scheduled according to its numbered sequence with the existing operations. If either a start or due date is specified for the new operation, rescheduling of the entire order is performed immediately.

If neither date is entered, rescheduling is postponed; due dates for the operation will be calculated by the appropriate scheduling logic.

If the new operation is linked to an existing master operation, then any required update to the master, or to the indicating flag on the new operation, is performed. The labor requirements are redisplayed with the new operation, and the workline is cleared. The user may perform further maintenance, or may request posting.

b. Add a master operation.

A master operation may only be added to the operations on an order when the operations with which it will become associated have not had labor or machine activity reported against them. There must be no consecutive master operation, and the operations to which the master will relate must already have identical crew flags.

Extensive validation is performed, including the operations that precede and follow the point at which the new master operation will be added.

If the new master operation is valid, the indicating flag of each active operation that is related to the new master is updated. The new master is loaded into the workfile in correct numerical sequence among the existing operations. (Since master operations do not affect the scheduling of an order, no rescheduling is necessary.)

The labor requirements for the order are redisplayed, and the workline is cleared. The user may perform further maintenance, or may request posting.

c. Add a new comment line.

A comment line may be attached to any active operation on the Labor Requirements file, as well as master operations. Both the system wide comment posting option and the function select comment display option must have been set to support comments (Y).

After the comment options have been checked, the comment line is validated. The workfile is checked to verify that the specified parent operation exists, and that the comment number of the new line does not already exist. If the parent operation is outside processed, Machine and Tool Numbers must be blank.

If valid, the comment line is loaded to the workfile, the subfile is redisplayed, and the workline is cleared. The user may perform further maintenance, or may request posting.

d. Update an existing labor requirement.

Only active operations, their comments, and the descriptions and comments of master operations may be maintained. To update any such record, the Sequence Number and Maintenance Code (U) are required. (Description lines, including tool and machine numbers, may be referred to either as part of the operation line or as individual entries.) See the Shop Floor Control User Manual for further validation rules.

The Sequence Number is validated to ensure that an operation exists and can be maintained. The data from the specified operation is retrieved and formatted for display in the workline. Only those fields that may validly be changed are input-capable.

Once the workline has been updated by the user, each changed field is validated; unchanged fields are cross-validated against changed fields. If all fields are valid, the changes are posted to the workfile.

If the updated record is an active operation, the start and due dates are checked to determine whether the order must be rescheduled. Rescheduling is immediate if either date has been changed and is not blank. After rescheduling, the entire subfile is reloaded. If neither date has been changed or if both are blank, rescheduling is performed only upon request. The requested changes to the individual subfile record are made in-place. (Description fields for each operation are held in the displayed subfile fields, and in hidden fields on the subfile description line and the active operation line.)

After the subfile records have been updated (or the subfile has been reloaded after rescheduling) any master operation that has been affected by the change is updated in the workfile. The screen is redisplayed, and the workline is cleared. The user may perform further maintenance or may request posting.

e. Delete an existing labor requirement.

The deletion of a record is requested by entering its Sequence Number and the Maintenance Code (D). This Sequence Number may refer to an operation, a master, or a comment, but the deletion of description lines is not valid. Neither may the comments of alternates be deleted unless the alternate has been activated previously.

A comment or alternate that is to be deleted is displayed for confirmation in the workline (input prohibited). At this point the deletion may be canceled by pressing F15.

An operation or master operation to be deleted is validated before the confirmation display. This validation ensures that there is no reporting data already on the record that would be lost when deletion occurs; it also ensures that the integrity of reporting data on other records will not be affected by the association of a master operation with existing operations as a result of the deletion.

If the record to be deleted was added during the same conversation, the record is physically deleted from the workfile. If the record was already on the file at the start of the conversation, the transaction code is changed to L35, and the physical deletion will occur at the time of posting. Following the deletion of a scheduled operation, any master with which it was the only associated record is also deleted; rescheduling of the remaining operations is made pending.

Following the deletion of any record, the subfile is reloaded. At this time those comments belonging to any operation, alternate or master operation that has just been deleted are also deleted. If comments are not displayed during the conversation, the posting program will delete them directly from the master file. The workline is cleared, and the user may perform further maintenance.

f. Activate alternate operations.

Operations that were defined as alternates on the Routing file may be activated to replace the standard routing operations for an order. This activation may be done on a one-for-one basis, on a many-for-one basis, or to replace the entire standard routing. Any alternate(s) selected for activation must however have been requested on the function select screen. If maintenance is being performed, the alternate(s) must have been posted to the Labor Requirements file when L/R's were first generated. Activating alternates does not retrieve new data from the Routing file.

Alternates are activated by entering the Sequence Number of the standard operation to be replaced, and the Maintenance Code (A). The Activate Alternate Operation Window program (AAOPWIN) is called to display a window listing the alternate operations for the selected operation. The user may select one, some, or all of the alternates for activationIf sequence number ALL is specified as the Sequence Number, alternates are to be activated for each standard operation on the entire routing. (Blank is invalid for the activation of entire routings.) Alternates may not be activated for any standard operation or routing that has labor activity reported, or for any already active alternate. See the Shop Floor Control User Manual for further validation rules.

After the user request has been entered, the workfile is checked to ensure the existence of the alternate(s) to be activated. The active/inactive code (CZACCD) of each alternate that can be validly activated is set to A; this ensures that the activated alternate will be included in future scheduling of the order.

If the alternates for all standard operations are to be activated, processing is determined by the direction of scheduling. If the order is forward scheduled, the alternates are activated, the operations being replaced are deleted, and the order is rescheduled in one pass of the workfile. If the order is backward-scheduled, the alternates are activated, and operations being replaced are deleted in a forward pass of the file; the order is then scheduled in a reverse pass of the file.

In either case, any labor requirement that is not part of the new routing is deleted; this includes all masters and the operations and comments that belong to the standard routing (or to other alternate routings). Any already active alternate that matches the new routing is left.

If only one operation is having its alternate(s) activated, a check is made to ensure that no activity has been reported against a master operation that is affected by the activation, or that the activation will not cause a workcenter break within a master operation. A further check is made to ensure that no master operation will have a mixture of crew and non-crew operations associated with it. Once the above validations have been performed, the alternate is activated. Rescheduling is not immediate; it will occur when requested.

The workline is cleared and the subfile is reloaded. The user may request further maintenance or posting.

g. Page to display a particular line.

Entering the Sequence Number of a line and the Maintenance Code (P) to the workline requests the display to page directly to the entered line. The Sequence Number must be less than that of the last line loaded into the subfile. Alternatively, entering END in place of the Sequence Number will display the page containing this last line.

G. Transaction Recording

1. Each valid maintenance transaction produces an entry on the Inventory Control Transaction Register, which will print in entry sequence.

2. The valid codes for user-entered transactions are:

L20	this record was added
L30	this record was changed
L31	this record was replaced by an alternate
L35	this record was deleted

3. Additionally the program will generate posting transactions. These will update the Labor Requirements file, but will not appear on the transaction register. The valid codes for these transactions are:

L21	this record was generated but not displayed
L30	this record was rescheduled
L34	this record has been associated with a different master operation
L35	this record was replaced, or is a master with no associated operations, or is a comment for a deleted operation

H. Rescheduling

1. During maintenance the changes, additions, and deletions to the active labor requirements are monitored. Any maintenance that alters data that will affect the schedule of any, or all, of the operations remaining for the order requires a reschedule of the order at some time before posting occurs. For directly entered dates, and for the activation of an entire alternate routing, this reschedule is immediate. The time used for any entered start date is the system Workday Start Time on the Warehouse Description Plant Validation file (IC170ML2). The time used for entered due dates is the earlier of workcenter workday end, or 11:59 PM. For all instances where no date is entered, any necessary reschedule is performed when requested by the entry of an empty maintenance workline.

2. Rescheduling as a consequence of an entered date is performed without reference to the scheduling direction of the order, and overwrites any dates entered previously. It is performed from the entered date; through the run time of the entered operation; and on to the end of the routing. This is followed by a reschedule from the entered date out to the other end of the routing.

3. Rescheduling for an activated alternate routing is performed in the direction indicated by the order header.* It is performed sequentially through the new routing, beginning from the start date of the first operation on the old routing (if forward scheduled) or from the due date of the last operation (if backward scheduled). Operations on the new routing that already have been activated have their dates overwritten.

4. Rescheduling for any other reason is performed in the direction indicated by the order header.* It only affects those operations that lie between the last remaining operation and the earliest altered, added, or deleted operation (if forward scheduled), or between the first remaining operation and the latest altered, added, or deleted operation (if backward scheduled).

I. Operations Associated With Masters

1. An active operation (that is, an operation whose active/inactive code (CZACCD) has been set to A by this program) may become associated with a master operation at any time before activity has been reported against the operation (that is, until the activity flag (CZACTR) has been set to Y in L/R Update).

2. The association occurs automatically whenever an operation is followed on the routing by a master operation, and no operation with a different workcenter or with activity reported exists between this operation and the master. The association becomes effective in the validation of future maintenance immediately; it may prevent subsequent maintenance transactions.

* For a more detailed discussion of order scheduling, see the Shop Floor Control User Manual: Labor Requirements Generation and Order Scheduling key concept.

3. Operations that are currently associated with a master bear the Operation Number of that master in their Detail-of-Master (CZDMOP) field. The association of masters and operations is only maintained by this program as necessary for validation; therefore, it is not always accurate. The posting program will reset all inaccuracies prior to posting.

J. Posting

1. Posting of the generated or maintained labor requirements records occurs whenever a blank workline is entered and no pending reschedule is indicated. There is no confirmation display before posting; a message and Manufacturing Order Asynchronous Transaction Record are written for processing by the posting program.

2. During both rescheduling and maintenance, the Start Date of the first operation remaining on the Labor Requirements file, and the Due Date of the last, are monitored for comparison with the Start and Due Dates of the corresponding manufacturing order. If either pair of dates does not match, the option to update the order dates is displayed when the posting of the labor requirements is requested. To avoid updating the order dates, the ENTER key is used. To perform the update, F19 is pressed. To request further labor requirements maintenance, F15 is pressed.

3. Posting of the labor requirements records displayed is not permitted if no changes will occur to the Labor Requirements or Manufacturing Order files as a result of the conversation.

K. Actual hours computation for batch sensitive fixed time operations (6 or 7):

1. Determine the number of batches required for the order.

NUMBER
OF
BATCHES

ORDER QTY — [BATCH QTY * (SENSITIVITY FACTOR/100)]
BATCH QUANTITY

Round the resulting calculation to the nearest whole number.

2. Compute for the length of time to complete a batch.

LENGTH
OF
TIME

NUMBER OF BATCHES * FIXED TIME LOAD
WORKCENTER HOURS PER DAY

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Labor Requirements Maintenance - Calculations

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