A production, or a producer, may be defined as an organization who produce one or more products through processing of different production factors. These production factors may be raw materials, parts or operations.

A production may result in

  1. Produced goods.

  2. Modified goods.

  3. Discarded goods.

A production order will most often be initiated through a customer order. In other instances the production order is ordered internally for stock.

A production order will in most instances, using parts, raw materials and operations, result in a finished product. If we take the car industry as an example, where a car is produced by combining own parts using in-house machines and their operative capacity, the whole production process is involved. In some cases the finished product needs to be modified, such as if a car model is faulty it needs to be recalled and modified. If a product is damaged in the production process, it can be scrapped and discarded.

Tasks relevant for the production process

  1. Register resources

    Resources in the production process, such as parts, machines, operations and personnel must be defined and set up before use.

  2. Register operations

    All available operations offered by the production company needs to be defined and set up before production.

  3. Maintain production structures

    Versioning and updating the content of products must be administered and maintained.

  4. Planning

    To deliver at agreed upon terms and time, the production needs to be planned in detail.

  5. Production

    The production itself is logged in a system to ensure traceability within the production factors, which again ensures a base for the invoice.

  6. Administer products

    Products which are produced or modified must contain information regarding production factors and information such as serial numbers.

  7. Following up cost of goods and time usage

    To create the base of the invoice as accurately as possible, all resources and goods needs to be priced accordingly.

  8. Deviation handling

    Handling defective goods or goods that need modification.

  9. Administer documentation

    There is a large amount of documentation involved in production, with instruction manuals, product certificates and measurement certificates. Which all needs to be administered.

Resources

In terms of production, a resource is a machine, an assembly area or an external capacity which can perform a task in the completion of a production work order. A resource needs to be configured before it can be implemented.

This process may result in

  1. A new resource is configured and ready for use.

  2. An existing resource is re-configured.

Different parameters may be attributed to a resource, which can be used to filter and trace the given resource. Among these parameters are classification, hour rate, capacity and operational capacity.

During classification of resources, it is important to state the nature of the resource, if it is a machine, a person (assembly, test, etc.). It is also possible to define resource group. A resource group may be similar machines, which are operated as alternatives to each other, such as a set of similar CNC machines, or a group of auto mechanics. In the latter example, the group may be called "Auto mechanics" and "Mechanic X" is a part of the group.

To control the resource cost of these resources, they must first be configured. An hour rate for a CNC machine may be set to 2500 NOK/hour and a mechanic may be 450 NOK/hour.

It is critical to define the capacity of resources, to avoid double bookings and the following delays and resource imbalance. For example, if you know the available capacity during the planning phase, you can state both expected start and end time of the production work order.

Tasks relevant for this process

  1. Create a new resource

    After purchasing a new machine, or setting up a new test station / assembly area, these must be defined as resources.

  2. Configuring resource

    The resource needs to be configured and classified.

  3. Activating resource

    After configuration, the resource needs to be activated to become operational.

Settings for Production- Resource management

Setting name

Description

Prepick Service Parts in Production

If setting is 'ON' - The user must mark 'parts included in a service' as picked before the service can be completed

Resources (RESCONFIG)

Production resources are set up, maintained and listed in the RESCONFIG application.

To open (RESCONFIG), select Production > Resource management > Resourcesin the RamBase menu.

Settings for distribution of work hours

Grouped Work order operations (WOO) in the Group work order (GWOO) application. To group WOO, the Allow grouping work order operations setting must be enabled in RESCONFIG. The operation time can then be distributed equally between the WOO in the group. To do so, the setting Distribute time on grouping must be enabled. This setting cannot be enabled if the parent setting Allow grouping work order operations is disabled. The quantity in each WOO is also taken into consideration. For example, for a group consisting of 2 WOO, if WOO 1 has a quantity of 1 and WOO 2 has a quantity of 2, then a combined operation time of one hour is distributed as 20 minutes to WOO 1 and 40 minutes to WOO 2.

Creating a new resource

  1. To open the Resource (RESCONFIG) application, find Production in the RamBase menu and then Resource management. Click Resources to enter the RESCONFIG application.

  2. Click the Create new resource button.

  3. This will open a popup, enter the name in the Name field and click the OK button.

  4. This will create a resource in status 1. Choose between External, Machine or Person in the Type field.

    • Optional, enter more information.

  5. Select the Activate option in the context menu to set the resource in status 4.

Add operators on resources

Use the Operators folder if one or several persons should be restricted to operate the selected Resource (RESCONFIG). All operators can use the resource if there is nobody added in the Operators folder.

By default only one operator can use a resource on a Production Work Order (PWO) at a time. Turn on the Allow multi operator, so that multiple operators can work in parallel on a PWO at the same resource. The Allow Multi operator checkbox can be found in the Settings area.

Add an operator to a resource
  1. Enter the Operators folder.

  2. Click the Add new operator button.

  3. Use the Operator lookup field to search for the person to add as an operator on the selected resource.

  4. Select the person you want to add as an operator and click the OK button.

Adding hourly rates for resources

You can view and change the hourly rates in the Hourly rates pane in the Resources (RESCONFIG) application.

Note

Unless you need to calculate cost, It is not necessary to add hourly rates for resources.

You have three Hourly rate fields where you can enter the hourly sates for the resource.

  • Setup

    This is hourly cost of the pre-work for this resource.

  • Main

    This is hourly cost for this resource.

  • Cleanup

    This is hourly cost of the post-work for this resource.

  1. When you enter a new value in any of the fields given above, the new value is set as Active in Status 4 and the previous value in the field is set to Status 9 (Deactivated). You can view all the values in Status 4 and Status 9 in the Hour rates tab.

  2. You can search for specific rates using the search query builder in the search field.

Restrict stock locations on resources

Restrict stock locations on a Resource (RESCONFIG) to only allow the resource to use parts that are located at the stock locations added in the Restricted stock locations folder.

Add restricted stock location on a resource
  1. To open the Resource (RESCONFIG) application, find Production in the RamBase menu and then Resource management. Click Resource to enter the RESCONFIG application.

  2. Select Restricted stock locations.

  3. Select Add new stock location.

  4. You can use the Stock location search field to search the restricted stock location(s). When you enter a partial name in the search field, a popup menu appears. You can search by Label, Name, Status, Description, and Stock Location ID using the query builder to build your search query.

  5. Select OK. The newly created stock location is assigned Status ST:4. Once you create a restricted stock location, you cannot delete it, only deactivate it, which sets the location to STATUS ST:9 (Deactivated). Select on the right side of a stock location to deactivate the location. The deactivated stock location is still present in the database. To view the decativated restricted stock locations, deselect . You cannot add the same active restricted stock location more than once.

Production resource group (REG)

Use the Production resource group (REGCONFIG) application to create and maintain production resource groups.

To open the Production resource group (REGCONFIG) application, find Production in the RamBase menu and then Resource management. Click Production resource group to enter the REGCONFIG application.

Create a new production resource group
  1. To open the Production resource group (REGCONFIG) application, find Production in the RamBase menu and then Resource management. Click Production resource group to enter the REGCONFIG application.

  2. Click the Create new resource group button.

  3. Enter a name in the Name field and press the OK button.

  4. Define the class of the resource group in the Type field. Choose between External, Machine and Person.

    • Optional, add more information.

  5. Select the Activate option in the context menu to set the resource group in status 4.

Add members to a Production resource group
  1. Enter the resource group where you want to add a member.

  2. Click the Add new member button in the Group members area.

  3. Enter the name of the resource you want to add in the Member lookup field.

  4. Select the member and click the OK button to add it to the resource group.

Workspace for production

An instant view of the factory

The PRODUCTION workspace gives the management a ‘status’ view of the factory and the current activities.  The tool gives information about key figures such as produced value, delivery performance, resource activity, delayed production and value of the delayed production, capacity utilization, measurement tools, reports ++ .  So the tool is applicable both for the CEO and the production management.  Needed permission to view the workspace is ViewProductionWorkspace.

Contents

The buttons in this section gives access to their corresponding applications:

Prodplan                         - The PRODPLAN application for production planning.

Resources                         - The resource (RES) menu.

Product Work Balances       - PWBAL application for work balances reports.

Delivery Performance                 - DPS, delivery performance statistics.

Measurement tools (MET) can be added to the system as a part of the production documentation module. Keep control of your instruments status and calibration dates in RamBase.

Click on the number of ‘Active tools’ to access the MET menu and use filters there to view e.g. METs needing calibration.

Active Tools                        - MET with status (ST) =8 are active instruments. Inspect on number goes to the MET menu.

Overdue/On hold                - Number of MET with Nextservice date that is before ‘today’

Within calibration window        - Number of MET with Nextservice date that is before ‘today’ + number of days that is specified in the company setting ‘ServiceWarningDays’.

Need calibration this month        - Number of MET with Nextservice between and including ‘today’ and the end of the current month.

Need calibration next month        - Number of MET with Nextservice within next month.

Pending measure documents        - Number of measurement documents (MSR) that are ready to be approved.

The ‘Key Figures’ section shows values for delivered (completed) productions, delivery performance, cost and time for planned production (forecast) and some figures for todays activity.

History

Delivered production

This is produced value for completed productions (SSA with DocType = PRODUCTION) with date matching the actual periods in the table. The calculated value is then the sum of the NetAmount for these actual SSAs. The sums are not calculated ‘on line’ but are stored values that are recalculated by a night batch job or by the recalculate icons at the Key Figures header.

The calculation routine checks each BOM (KIT) for sub KITs and reduces each SSAs value with any found cost from the subs that are produced internally to ensure that the produced value is not ‘doubled’ and that the values are correct within the actual periods. Purchased articles with Class = K* are calculated as any other ingoing part/material (not production).

Delivery performance %

Delivery performance (DPS) for customers in percentage, sum of early + on time.

Forecast

Resource plan h/%

These values are calculated from resources (RES) that are not group resources (only members and single resources) and that are classified as active (ST less than 9).

Hours/

      = planned hours = sum of all Used (DayUsed) hours for dates within the rest of the actual period.  Found in the ‘Usage’ folder at each RES.

/utilization rate                = sum of DayUsed divided by sum of DayCapacity * 100 (%) for the resources and rest of the actual period.

Production cost plan

These values are showing the sum of planned cost for planned and running productions. PWO that are confirmed and active and that have status >1 and < 9.  Sum of the PWOs NetAmount and as for delivered production this is also reducing the value for each PWO with value for used sub KITs.

ProdEnd (calculated production end date) decides in which period the value is included.

The Delivered production and the Production cost plan values can also be shown as graphs by clicking at the graph icon at the section header.

Green                material cost and added material cost for production history (completed production).

Orange                operation cost for production history (completed production).

Blue                planned material cost and added material cost for the production plan. Running and planned production.

Red                operation cost for the production plan.

Today

These two speedometers shall indicate how the available resources are utilized today and indicate how the reality meets the planned utilization.

Active resources                Number of resources with running or paused jobs

Active operations                Number of running or paused jobs

Delayed production (cur)                The value of production orders where at least one of the operations is delayed with 1 day or more compared to planned for the operation.

Completed % prod/

orders total                        For running / released production orders, PWO with status (ST) > 5 and < 9.

                        Accumulated accrued time / accumulated planned time * 100.

                        Result > 100 = overused time.

Speedometer 1

Planned utilization for all resources today.

Utilization = sum DayUsed / sum DayCapasity * 100 (%).

Speedometer 2

Logged time today compared to planned time today.

Sum logged time / sum DayUsed * 100 %

The boxes below the speedometers

These boxes will show some numbers and figures, some of them with inspect possibility, for number of production orders, production orders waiting to be released for production, delayed productions, production value of delays, quality reports.

Ready for production:      PWO with ST = 4, PRODSTART <= today

Running productions:       PWO, ST=5

Completed productions: PWO, ST=8

Operations: Planned operations waiting for preceding operation to be completed.

Resources:   Resources with waiting operations.

Production

orders:          Work orders (PWOs) with waiting operations.

Operations:  Active or waiting operations that are delayed compared to planned start/complete date.

Resources :  Resources with delayed operations.

Production orders: Work orders (PWOs) with delayed operations.

The first three lines in the list are representing the same numbers as in the Delayed productions box above but here including the value of the delayed production orders behind these numbers.

Inspect on the numbers at line 1 and 2 goes to PRODPLAN and folder Delayed operations.

Inspect on the number at line 3 goes to PRODPLAN and folder Delayed productions.

Delayed pending orders:

This is the number of customer order items or production orders that are linked to Pending, meaning that a production work order (PWO) needs to be created for this.

Inspect on the number at line 4 goes to PRODPLAN and folder Pending by Order.

Delayed external work:

Active or waiting external operations that are delayed compared to planned start/complete date.

Inspect on the number at line 5 goes to PRODPLAN and folder External Operations.

Overdue quality reports                This is the number of QAR documents that are not closed (ST < 9)

                        and where DUEDATE < today.  Inspect to the QAR menu.

Cost deviation

Number of operations with cost deviation alert.

Inspect to report REP/102680

Time deviation

Number of operations with work log alert, that is operations that have been completed and the difference between logged work and planned work is higher than the company setting.

Inspect to report REP/102681

REPORTS:

The reports section shows links to group of reports related to sub modules that are part of the production module.

Operations

In terms of production, an operation is a single task in (normally) a series of tasks in the production process. A production process may also consist of a single operation. The operation usually consist of work and parts. An operation needs to be defined and configured.

This process may result in

  1. A new operation is configured.

  2. An existing operation is re-configured.

When an operation is classified, it may be classified as a test operation, a production operation, a package operation, or an external operation. For example, during production of a computer screen, the soldering of a circuit board will be a production operation while an external operation may be the assembly at a different location. The test operation is the testing and approval phase before shipping the product.

Operations need to be priced according to the production situation the operation is used in, but to set a customer specific price is also possible. This allows for two prices on an operation, to service customers who has negotiated better terms. Cost price must also be in relation with the time usage for the operation, which differs from productions. Time usage for preparation and after work also needs to be defined, as it all adds up to time used in the operation.

Tasks related to this process

  1. Create a new operation

    If the company acquires new resources which enable the company to perform new tasks, these must be configured as operations.

  2. Configure operation

    The operation needs to be configured, with price, classification and resource usage.

  3. Activating the operation

    The operation needs to be activated to be ready for use.

Settings for Production- Operations management

Setting name

Description

Move mode for Operation Planner

"Value in this setting for 'Movemode for the PLANNER/GANT' must be one of these alternatives:

MINIMAL: Only move this Almanac (ALM) element, do not touch the remaining operations, unless this element is moved in front of/after an adjacent operation, in which case those operations affected will be moved according to the rules of PACK.

SINGLE: Only move this Almanac (ALM) element, fail if moved across prev/next.

SIMPLE: Only move this Almanac (ALM) element, do not touch the remaining operations, dont care about conflict. Even possible to move started Operations or move them to before SYS.DATE/TIME"

Operation ID used in Rework

Value in this setting is a default Operation (OPR) needed to perform a Rework Production Work Order

Production Work Order Picking Operation ID

Value in this setting must be the Operation (OPR) that should be used in the structure for new Products (ART) that is loaded from PDM systems (CAD-design). The files only contains the parts that should be used in the Product, and the Operation will be picked from this setting

Wait For External Planner to start Operation

If setting is 'ON' - operations should be put on hold until release-signal is given  from the external planner.

Operations (OPR)

An operation is a unit of predefined work that is required in the production process. An operation can involve several parts and/or raw materials, and is linked to a resource or resource group. The OPR application contains information about all operations in RamBase.

To open the Operations (OPR) application, select Production > Operations management > Operations from the main menu.

  1. To search for a specific operation, enter the search criteria in the search field. A popup appears. You can create a search query by using the search criteria given in the popup.

  2. To create a new operation, select .

  3. Enter a descriptive name for the operation in Name.

  4. Select OK. The new Operation is created with status ST:1. You can see the new operation at the top pf the operation list.

  5. The Production Operations Details pane gives the following fields, drop down lists and control groups.

    1. Description. Enter a description of the operation here.

    2. Type. Select the type of operation from the list. If you select External, you are only shown external resources in the Resource lookup.

    3. Applies to. Select if the operation is related to either a production resource or a resource group.

    4. Resource is displayed if Resource is selected in in Applies to . Select the resource by using the Resource lookup. Select to open the Production resources (RESCONFIG) application, where you can see more information about the selected production resource.

    5. Resource Group is displayed if Resource Group is selected in Applies to. Select the resource group by using the Resource group lookup. Select to open the Production resources group (REGCONFIG) application, where you can see more information about the selected production resource group.

    6. Set next operation ready. Specify the Value and Unit here. For example, if you specify 5 pieces, then the next operation in the sequence is automatically set as ready when the current operation is completed on 5 pieces.

    7. Settings. You can set a Checkpoint and name it. The checkpoint halts the operation until a certain task is completed. You can name the checkpoint task in the description. For example, once your operation is commenced, you can add a checkpoint to halt further operations until a quality assurance process completes.

    8. Require picking before completion. If this option is selected, then all the necessary parts for this and previous operations must be be picked before the current operation can be completed

    9. Require serial number before completion. If this option is selected, then all items in the tracelist for all product units must have a serial number assigned.

    10. Processing. Specify the Run time, Setup time and Cleanup time for this operation in hours. You can also use decimals such as 0.2 hours etc.

    11. Alternative resources. Select to add alternative production resources that can be used for the operation if the main production resource is unavailable. For example, this can be a substitute machine or operator.

    12. Added cost. Select to add an additional costs accruing from this operation. The additonal cost can also accrue from the use of alternative resources. The additional cost is displayed in the product structure of products that contain this operation.

  6. Select Operations > Activate in the context menu to activate the operation and set it to Status ST:4. You must specify the following mandatory information before you can activate a production operation - Type, Applies to, Resource or Resource group, Run Time and Setup time. You can edit an activated operation by selecting Operations > Open for edit.

The other options available in the context menu are as follows.

  1. Inspects and views gives the following options.

    1. Experience data. Select this option to open the Quality Report Archive Menu - Experience data application.

    2. Revision history. Select this option to view the revision history of the operation.

    3. Included in structure. Select this option to open the Kit menu application.

Create a new operation

  1. To open the Operation (OPR) application, find Production in the RamBase menu and then Operations management. Click Operations to enter the OPR application.

  2. Click the Create New icon to open a new empty operations window.

  3. Add details to the fields in the Main section.

    1. Type the operation’s name in the Operation Name field. This is mandatory.

    2. Optionally, add a description of the operation in the Description field.

    3. Select class from the drop-down menu in the Class field.Note: During Class selection, be careful to pick the correct class as it may be impossible to change after. This is evident in the EXTERNAL class where the class is set and not changeable after it has been defined and used in a kit. It does not matter if the kit is ST:9.

    4. The ProductIdForExternalOperation field is only used in instances where External is chosen as Class.

    5. The Complete Picking First check-box is used in situations where the picking of materials/parts must be completed before starting the next operation.

    6. The Set Next Operation Ready field is used when you want to set the next operation as ready before the current operation is completed. Enter the degree of completion (value and unit e.g. 60 % of Qty) you require in order to set the next operation as ready.

  4. To select the resource for the operation, click the Select Resource-icon (located next to the Production Resource field).The Resource Select window will appear.

  5. The Time section is used to define the time needed to complete the operation.

    1. The Time field states the total time usage for the operation, per unit.

    2. The PreTime field is used for preparation of the production, independent of the number of units.

    3. The PostTime field is used for the post production time usage, such as cleaning and removing the tools.

  6. Click the CheckPoint-box in the Miscellaneous section to indicate that you would like a hold-point in the production, where the user/operator is confronted with the message you entered in the CheckPointDescr field. The check point must be approved by the user/operator before completion of the production.

  7. When all necessary fields in the Operations window are filled in, activate the operation by pressing F12 to bring up the action menu and choose the option Activate.The mandatory fields are Operation name, Production Resource, Class and Time.Note: To edit the Operation after activation, use the F12 option Open to Edit to return the document to ST:1.

Queue time

The Queue Time (QUEUETIME) application is used when a certain operation needs a certain waiting period before completion, either an accompanying operation or by it self.

Type QUEUETIME into the program field and press ENTER to open the application.

The header allows you to enter a default queue time between all operations and/or a default queue time after all operations if needed.

The queue time without a second operation is the queue time after Operation 1. Queue time with a second operation is the queue time between the two operations.

  1. Click the Create new QueueTime icon.

  2. A popup will open where you can add an operation using the Previous Operation icon. Select the operation from the operation menu.

  3. You will then be able to enter the exact queue time for this operation.

  4. If the queue time is only valid if Operation 1 is followed by another specific operation, you can add this using the Next Operation icon.

The operations are visible in the item lines after you have entered the operations. The columns indicate the operations number and the specific queue time.

Cost and price of operations

The cost of an operation is the operation time multiplied by the resource hour rate.

In some cases there are added costs involved, and these can be defined in the folder Added Cost in the Operations (OPR) document.

Clicking the icon Add Additional Cost will prompt the Select Additional Cost popup. Here you can find defined added costs which may be added to the operation in question.

When you are in the process of adding operations to the kits which are to be produced, the added costs defined in OPR will follow the operation automatically.

If you have added the operations and parts to the kit already, it is also possible to add the added costs in the kit window, when it is still in ST:1 using the Plus icon in the item line under the Itm column.

Note that added cost in a structure is a global value, so it will change in all other structures with added cost.

Set up external work

External operations are used when the company needs work done which they cannot, or do not have time to perform themselves. This applies whether the operations are performed by a supplier coming on site, or the product is sent out of the house to have the operations performed at the suppliers location.

Set up an external operation
  1. If not already created, a new resource needs to be created for the external operation. To open the Resource (RES) application, find Production in the RamBase menu and then Resource management. Click Resources to enter the RES application. Create a new RES as normal, but use External in the Class field to categorize this as an external resource.

  2. To open the Operation (OPR) application, find Production in the RamBase menu and then Operations management. Click Operations to enter the OPR application. Create a new OPR as normal, but use External in the Class field to categorize the operation as external. Using the External class will create an article with class WX. Note: During Class selection, be careful to pick the correct one as it may be impossible to change after. This is evident in the EXTERNAL class where the class is set and not changeable after it has been defined and used in a kit. It does not matter if the kit is ST:9.

  3. Enter a value in the Time field. This value will not be the base for the operation cost, as the purchase order price/invoiced price will be the base for the external operation cost.

  4. The Freight Parts tab is used to enter the freight prices. This is mostly used when the part will be sent. This option requires you to have made an article class=XF (External Freight) before the freight is added.

  5. The operation is now ready to be added to the product that needs external work. Locate the structure in question and open it.

  6. Click the Kit button next to the Class field. If this article has yet to be defined with a structure, you will need to do this. If the article is already set up, this will open the Kit Designer with the full structure. To be able to edit this structure, it either needs to be in ST:1, or you will need to make a copy of the structure using the Copy Version button on the top. This will create a new version of the structure.

  7. With the structure in ST:1 (editable mode), open the Designer tab. The default choice of viewing here is Parts, so you will need to click the Operations button on the top to change to view operations.

  8. To make things easier, use the dropdown menu in the OpClass field to filter by class: external using the EXTERNAL option.

  9. Click and hold the Class icon (the factory) of the desired operations and drag it into the structure to the left.

    • If you need to change the placement of the operation in the structure, return to the Kit Details tab and choose the item line and press ENTER. Enter the desired value in the OpNo field to place it within the desired range.

  10. Finish the structure as normal with approval and activation. The product is now in ST:4.

When a production order is created for the product, the external operations will show up in the Purchase (PUR) application in the External Work folder.

Note: If there is a need to change the price of the operation, it is possible by entering the kit, choosing the operation item line, pressing ENTER and editing the price in the Price field. The criteria for this action is that the kit is in ST:1, which can be done by making a new copy, which will be in ST:1.

Perform external work

Purchasing

All purchasing for external work is done in the Purchase (PUR) application, using the External Work folder. To purchase external work for Production Work Orders (PWO):

  1. Open the Purchase (PUR) application, by selecting Procurement > Purchasing > Purchase handling.

  2. Select and select Pending orders.

    • You can also purchase for specific PWO by using the PENDING link in the Kit Linking view from PWO.

  3. Check off the item lines you want to purchase for. Click the Select Action button when finished. Click the Make Order button in the popup. You also have the ability to remove item using the Remove Item button to the right of the item.

  4. Choose the supplier for the order(s). Click the Start Action button when finished. This is a bulk action and will create Purchase Orders (SPO) for all the item lines.

  5. Open the newly created SPO and register it the same manner as a normal SPO. Use the Change ship to address for external work-option to change address if needed.

When the products have been received back from the supplier, the operation is ready for completion.

There are two blockers for completing the production:

  1. You will not be able to start the operation before the external work is ordered.

  2. You will not be allowed to complete the operation before the total quantity is received from the external operation.

Serial numbers

The serial numbers from the productions will be copied to the serial number table of the SPO when the SPO is registered. if the Life Cycle Management (LCMs) for the PWO is created after the SPO is created, the serial numbers will be copied to the SPO / Purchase Order Response (SOA).

The serial numbers will also be copied to the next document in the process (Supplier Return (SRT) and Goods Reception (SSA)).

Splitting quantity on SPO

To split quantity from the SPO, you will have to manually select which serial numbers that are received. This is done for example in instances where partial orders are received and need to be registered.

  1. Open the SPO.

  2. Click the Transport Item to Another Document icon to the left in the item line.

  3. This will open a popup where you need to choose the target document.

  4. After the document has been chosen, you will see another popup where you can administer the serial numbers. You can see the available serial numbers and an icon called Choose SerialNumber. Click this icon and choose which serial numbers you want to register.

  5. Click the OK button when finished.

Prodplan folder External Operations

Here you can see the different operations related to the productions with external work. Filter the results using the magnifying glass icon. From here you may enter a Pending PWO and continue with the process, or check the status.

You can also enter the External Work Logistics, which is available using the Note icon to the far right in the item line. From here you may:

  1. Change Req

    Change the required delivery date.

  2. Change SHIPTOSUPDATE on SPO

    Change the date for when you want to ship the part to the supplier of external work.

  3. Change Conf on SOA

    This option will change the confirmation date on the Purchase Order Response (SOA).

  4. Create SRT for this operation / PWO

    Will create a Supplier Return (SRT) document in ST:1. Will set the operation status to 5P: started and paused.

  5. Create SSA for PO item

    Creates SSA for PO item and registers it to ST:3 in addition to completing the operation to OPST:9 if full quantity is received.

Shipping to supplier

The folder Ship External Work in Production Planning (PRODPLAN) is used for shipping to supplier. This application shows SPO / SOA items not yet shipped.

  1. Select the desired items using the checkboxes.

  2. Click the Select Action button at the bottom.

  3. This will open a popup where you can review your choices, and remove unwanted items.

  4. Click the Ship button when finished and the Start Action button on the next popup to ship the goods.

Receiving from supplier

Reception from supplier is done in the Goods In (GIN) application. This action must only be taken if the full quantity is delivered. If not, please use the manual transport at SPO / SOA item.

  1. Select the desired items using the checkboxes.

  2. Click the Select Action button at the bottom.

  3. This will open a popup where you can review your choices, and remove unwanted items.

  4. Click the Register button when finished and the Start Action button on the next popup to register the goods.

External work - Operation handling and logistics

An external work order operation is an operation done by a supplier to a product in the Production work order (PWO).  The product is sent to a supplier for this operation or the supplier runs the operation at your own site (in house external operation). This implies that an external operation includes processes for purchase, outbound logistics and inbound logistics.

Changes to the procurement and logistics process

We have made some changes to the procurement and logistics processes.

The main changes are:

  • The serial numbers are not copied to the Purchase order (SPO), Therefore, there are no serial number requirements for any step in the purchase and logistics processes.

  • Full flexibility to do partial shipments to the supplier. The shipments are not connected to the Sales order responses (SOA) items if they exist, only to the original SPO.

The sections below describe the applications that are used for handling the external operations and the processing of these operations based on the implemented changes.

Procurement processes:  purchase order, order confirmation

The Purchase (PUR) application has a tab for creating Purchase orders (SPO) for external work.

It is pre-filtered for the work order and operation if accessed directly from the pending link in the assignment list in the PWO, but the tab also features filtering and a multi-selection tool for creating Purchase order (SPO) for multiple work orders.

The result is always one SPO item per combination of a specific work order (PWO) and operation number.

Order confirmation from supplier

The order confirmation from the supplier is handled by standard applications and methods. Transport the SPO item to a Supplier order confirmation (SOA), and it can be split to several SOA items if the supplier confirms partial delivery of the ordered quantity. The same rule applies to the SOA items, one SOA item is only valid for the combination of a specific work order and operation number.

External work logistics overview

The Production work order (PWO) has no special link to the logistics view for external operations. The operations are purchased, confirmed and received and this is displayed as for the parts of the PWO BOM in the list of assignments to the PWO. The Work order operation (WOO) has a link to a view of the external work logistics:

The external work logistics application shows all the purchase and logistics details for the operation, the purchase orders, the shipments to the supplier, the received quantity and information about the previous and next operations and the scheduled dates for the operations.

Create Supplier returns (SRT) for shipment to the supplier

It is not mandatory to create SRTs for shipment to the supplier. However, create SRT when the products are shipped by some means of transport and whenever there are partial shipments for external operations.  There is no need to shipping products if the supplier is doing the operation in-house at your factory. The reference for the shipments is the Purchase order (SPO) for the operation, so even though the application shows multiple lines for creating SRT, there is only one total summary for shipments to the operation. The Create SRT button opens a popup to create SRT for the quantity to be shipped and where the reference to the shipments is shown.

Please note that the Create SRT option is displayed at each PO line for the operation, the shipment is not done to one specific SPO item or SOA item, the shipment has only reference to the SPO and the quantity to be shipped does not have to match the quantity of one specific SOA item.

Shipments where parts/material must be picked and shipped together with the products

Parts and material that shall be picked and shipped together with the products have to be added in the BOM (KIT) as material lines to the external operation. These parts are assigned to the Production work order (PWO), but are also added to the SRT as items to be shipped. But: The SRT items do not have any stock assignments, it is only a delivery note for the external operation. That means that the picking process is done on the PWO.

The picking is initiated when the first SRT is created for the operation, and technically because that starts the external operation, and starting the operation is the trigger for initiating picking.

Note:

  1. The picking of these parts must be added as a routine when handling the shipment, and the picking process must be done from the PWO.

  2. If there is a partial shipment for the external operation, the SRT items will have quantities of added parts that are matching the number of products to be shipped. But the picking is initiated for the full quantity (quantity linked to stock) and the user must reduce the picked quantity in the picking application. The balance will remain unpicked, but still initiated and locked for the next shipment where the user then must confirm more of the quantity as picked.

Change picked quantity and confirm:

Receive products from external work – Create SSA

Products can be received from the supplier in any quantity, and the quantity does not necessarily have to be the full quantity from a specific PO item (SPO or SOA). But the reception is done from one of these items as they need so be closed (completely received) at some time before the operation can be completed. In the example below we have selected Create SSA at one SOA item with quantity = 10. This SOA item is then the reference in the create SSA popup and 20 is suggested as quantity to be received:

We reduce the quantity to receive 6 pcs, the popup is refreshed and available quantity to receive for this SOA item is now 4 pcs.  Select the Esc key to go back to the overview and it will show the result of having received 6 pcs for the SOA item:

There is no option to receive in total a higher quantity than ordered for the external operation. The operation is automatically closed (done) when the last goods reception is done. There is also no option to, for example. receive 15 pcs and select that 10 pcs is from one SOA item and 5 pcs is from another SOA item/SPO item.  The source of a SSA item is only one item, it can not come from two PO items. A more flexible selection method will be evaluated for next version, but the result will always be that one SSA item can only have one SOA/SPO item as source. But an SPO/SOA item can have several partly deliveries, several SSAs.

Complete the operation

The operation is automatically closed when the last products are received to stock.

Add operation time on a PRODSSA item

In instances where the product needs to be delivered before all documentation has been completed, operation time can be added after the document has been closed (ST:9). Documentation is included in the total cost and is included as a unique operation in the production structure.

The criteria:

  1. Goods reception (SSA) document with doctype=production (PRODSSA).

  2. ST:9 (completed production work order).

Add time to a PRODSSA item
  1. To open the Goods Reception (SSA) application, find Logistics in the RamBase menu and then Reception. Click Goods receptions to enter the SSA application.

  2. Find the SSA document you want to add time to in the menu and press ENTER.

  3. Enter the SSA-Item, which is the Production Work Order (PWO) document.

  4. Press F12 to open the action menu and choose the option Add Operation Time.

  5. This opens the Add Operation Time popup. Use the dropdown menu to the right to choose the operation you want to add time to.

  6. Three field will then be open for input:

    1. StartDate: Enter the date the extra work was performed (can not be a date later than the current).

    2. StartTime: Enter the start time for the work done in the form HH:MM.

    3. Workhours: Enter the total amount of work time in decimal form.

  7. Click the Confirm button when finished.

  8. Gross margin (GM) at linked sales order, CostPrice on the SSA and stock value of the SSA will then be adjusted accordingly.

The Work Order Operations (WOO) Application

The WOO application is used by shopfloor and other production personnel to monitor and interact with the planned work order operations. It is optimized for easy viewing in shopfloor conditions.

The image above shows the WOO application screen with the Production Work Order (PWO) on hold in the picking stage. The colored band at the top is color-coded to show the status of the WOO. An icon followed by the operation and status is given. Hover over the icon to see the status details.

There are several fields and buttons given below the status bar.

  1. Production work order. You can see the details of the PWO here. Select to open the PWO application.

  2. Product name gives the name of the product associated with the work order operation. Select to open the Article (ART) application. Refer to Article (ART) for more information.

  3. Product revision gives the product revision used for this Production work order.

  4. Product description gives the description of the product used in the WOO.

  5. Quantity gives the quantity of the products used in the operation.

  6. Production resource gives the resource assigned to this operation. Select to open the Resource Work Order Operations (RWOO) application where you can see the list of work order operations assiged to this resource. Refer to Resource Work Order Operations (RWOO) for more information.

  7. Operation gives the name of the operation in the WOO. Select to open the Production Operation (OPR ) application where you can see the details of the operation. Refer to Operations (OPR) for more information.

  8. Customer reference number. This is the customer's order reference. If the production work order is derived from a sales order, the customer's order reference will be the same as in the sales order. This is typically a reference to an external system.

  9. Run group gives the name of the run group if several work order operations are grouped to be run together. Select to open the Group Work Order Operations GWOO application. Refer to Group Work Order Operations (GWOO) for information on how to group Work order operations.

  10. Service product unit gives the details of to the service product if the Production work order refers to a service. Select to open the Life Cycle Management Menu (LCM), where you can see the details of the service.

  11. If the production work order that refers to a service is in status ST:8, select COMPLETE SERVICE to set the status of the Production work order to Completed.

  12. Checkpoint gives the checkpoint specified in the Operations (OPR) application, Select Approve to approve the checkpoint.

  13. Drawing is visible if there are drawings or photographs attached, such as CAD files or assembly drawings.

  14. Cost deviation gives the deviation of the accrued costs of the production operation from the planned production cost estimate. Select the cost deviation figure to open Cost Deviation Approval, where you can select Approve to approve the cost deviation.

  15. On hold reason gives the reason for stopping the Work order operation. You can enter the reason when you put a Work order operation on hold.

  16. PWO on hold reason gives the reason for stopping all the Work order operations in the PWO. You can enter the reason when you put the PWO on hold.

  17. Select Material assignments to open the Production Work Order Assignments (PWOSARLINKS) application, where you can see the Product name, Product Description, and Remaining Quantity.

  18. Select Work order quality reports to open the Quality Report Archive Menu (QAR), where you can view the details of quality reports from the WOO.

  19. Select Product quality reports to open the Quality Report Archive Menu - Experience data (QAR).

  20. Previous operation product placement gives the location of the product during the previous operation. This might be on a specific machine or shopfloor area.

  21. Product placement gives the present location of the product. This is an input field where you can enter the location of the product before the next oeration commnces.

  22. Select the operator in Operator. If Allow Multi Operator is selected in RESCONFIG, the multi operator feature is enabled in WOO, and more than one operator can work on a Work order operation. The selected operator's work log starts when you select START, and stops when you select PAUSE. When all the work log is completed, the COMPLETE button is enabled and you can select COMPLETE to set the WOO to ST:8, (COMPLETED).

  23. Select SET READY to set a Work order operation ready for commencement.

  24. Select PAUSE to pause the WOO. This can be a pause while a machine breakdown is repaired, or while a painted part is drying.

  25. Select START to start a WOO.

  26. Select CONTINUE to restart a paused WOO.

  27. Select COMPLETE to set a Work order operation to Completed, Status ST:9.

  28. Select ON HOLD to temporarily halt a WOO, pending some other action. For example, you can put a WOO on hold until some test procedures are completed. You can enter a reason for putting the WOO on hold.

  29. Select ON HOLD OFF to restart the WOO:

  30. Select UNDO to undo any changes you make to the WOO. Some changes cannot be undone.

  31. Select RESCHEDULE to change the planned start date of a Work order operation.

  32. Select SCAN PICK to pick parts for the WOO by scanning using a Handheld terminal (HHT).

  33. Select PICK to manually pick parts for the WOO.

  34. Select END WAIT TIME to end the wait time for any operation in a WOO. For example, the wait time can be applied when parts are painted or glued, to allow time to dry. This wait time is specified in QueueTime in KITDOC.

  35. If the WOO applies to a service operation instead of a production operation, select COMPLETE SERVICE to end the service operation. This button is enabled only for service work orders set in in ST:8 (COMPLETED).

  36. When the Production work order (PWO) is in Status ST:8 (COMPLETED), the Forward to goods reception button is displayed. Select Forward to goods reception to forward the products to an unassiged stock location, or select to lookup the necessary stock location and select Forward to goods reception to forward the products to the necessary stock location.

    Note: The Forward Work Order to Goods Reception Company setting (CSV) and Move To Stock Location child setting need to be activated in order to have these options available. A preferred stock location needs to be defined on the Product (ART) in order to have a predefined stock location given in this step.

  37. Version note gives the note attached to the version of the product in the KITDOC application.

  38. Operation note gives the operation note attached to the product in the KITDOC application.

  39. Previous work order operation gives the previous work order operation in the sequence of production work order.

  40. Next work order operation gives the next work order operation to be done in the sequence of production work order.

  41. Attachments gives the various attachments that are attached to the WOO. related Operations (OPR), (PWO), Article (ART), (KITART ) and Lifecycle management menu (LCM). These can be items such as document files and notes.

  42. Measurements gives the various measurements captured during the testing. It also gves the product serial number and name. Select Complete to set the operation as completed.

  43. Select Inspect Worklog in Work time to open the WorkOrderOperation TimeLog where you can view the planned hours, accrued hours, work start and end times, operator names etc for the work order operation.

  44. Select Inspect Manhours log in Work time to open the Manhours log where you can select the operator to view the WorkStart, WorkEnd, as date and time, times, Total hours worked, Work Step (Preproduction Production or Post production), Hours Type (Standard or Overtime/Weekend). You can add new lines to the Manhours log. Add line is enabled if the Production resource's setting Allow man hours is enabled in Resource configuration RESCONFIG.

  45. Work time also give

    s the total Run time and Additonal man hours worked, if any.

  46. Today's production resource usage gives the Used resource time or the resource turnover for the day, according to the settings.

  47. You can reopen a WOO in Completed (ST:9) status by selecting REOPEN.

  48. You are prompted to specify the reason for reopening the WOO. You can select from an existing reason or enter a new reason for reopening. If you entera a new reason, it is added to the list of exisiting reasons. The ViewWorkOrderOperationReopenReasons permission must be enabled for you to view the reasons for reopening the WOO. To change the reason for rYopening the WOO, the CreateWorkOrderOperationReopenReason permision must be enabled.

  49. The WOO is set to one status back. This could be Status ST:5, Processing, Status ST:7, if the WOO has post-operation cleanup processes, The status could also be set to Status ST;4 Setup or Status ST:8 Wait time..

The Worklog application (WORKLOG) for Work Order Operatins (WOO)

WORKLOG enables you to manage the work log, which is created when you start any Work order operation (WOO). You can also manually add a worklog record.

  1. Select Worklog in the Work order operation (WOO) application to open WORKLOG.

  2. WORKLOG displays the operator name, start time and end time, if any operations are started, There are three types of Work step:

    1. Setup. Status ST:4.

    2. Processing. Status ST:5.

    3. Cleanup. Status ST:7.

    The Setup, Processing and Cleanup times must be specified in the Production Operations (OPR) application as shown below. The times are multiplied by the number of products to derive the total times. For example, if the Run time is one hour, and the Quantity is 10, then the total Run time for the production is 10 hours.

  3. To manually add a worklog record, in Worklog, enter the Start at, Worked time, Operator, Work step, Manhour rate type and Note, then select Add.

  4. To add a new Manhour rate type, open the Resources (RESCONFIG) application, in the Manhour types tab, select Add new manhour type. Enter the Manhour type and Rate and select Create.

  5. Select to edit an existing worklog record. You can change the Operator and Hours. You must enter a note when you make any changes to a worklog record. You cannot save the changed record without entering a note. Select to save your changes.

  6. Select the Revision history icon to see a history of changes to the worklog record.

  7. Select to apply the following filters to the view. You can remove a filter by selecting X in the filter label.

    1. Cleanup. See all the worklogs for clean up tasks in Status ST:7.

    2. Machine. See all the worklogs that are logged by selecting the Start and Complete. these worklog hours are calculated separately from the Manhours worklogs.

    3. Manhours. See all the worklogs for work hours added manually.

    4. My worklogs. See all the worklogs related to me.

    5. Processing. See all the worklogs in Status ST:5.

    6. Setup. See all the worklogs in Status ST:4.

    7. Started today. See all the worklogs that were started today.

  8. The progress bar gives the Total hours worked. This does not include worklog hours entered manually. To enter manhours manually, the Allow man hours setting must be enabled in the Resources (RESCONFIG) application.

  9. The upper area of the WORKLOG window gives the following information.

    1. Operation name. the name of the operation is given here.

    2. Sequence Number. The sequence number of the operation is given here.

    3. Started at. The date and time of starting the operation is given here.

    4. Finished at. The date and time of completion of the operation is given here.

    5. Setup time. This progress bar show the logged setup time against the planned setup time. The progress bar is green If the setup time is less than planned, and red if the setup time exceeds the planned time.

    6. Run time. This progress bar show the logged run time against the planned run time. The progress bar is green If the run time is less than planned, and red if the run time exceeds the planned time.

    7. Cleanup time. This progress bar show the logged cleanup time against the planned cleanup time. The progress bar is green If the cleanup time is less than planned, and red if the cleanup time exceeds the planned time.

    8. Total time. This progress bar show the automatically logged total operation times against the planned total operation time. The progress bar is green If the total time is less than planned, and red if the total time exceeds the planned time.

    9. Total manhours. The total manually logged hours are given here.

  10. Select the Copy entry icon to copy a manual entry. You can see the details in the Worklog pane. Change any information as necessary and select Add to create a new manual worklog record. This feature is useful when you want to create similar worklog records.

  11. Select the Show revisions icon to view a history of the changes to the worklogs.

  12. In the Production Work Order PWO) application, there is an option to split the Production work order (PWO). If you split a PWO, If the PWO is split, then the worklogs must also be split because hours already logged must be split between two worklogs. In the notes, you can see that the worklog was Transported from a PWO. The Show split worklogs icon is also visible for a split worklog. Select Show split worklogs to view the PWO to which the split worklogs are assigned.

  13. Enable the Use legacy worklog setting in the CSV application if you want to use the legacy WORKLOG application, in case of issues when using the new WORKLOG application. This setting is automatically removed if you do not enable it for a certain period of time.

Group Work Order Operations (GWOO)

The Group Work Order Operations (GWOO) application is used to group multiple Work order operations (WOO) together. This enables you to start, pause, stop or complete all the WOO in the group simultaneously.

How to group Work Order Operations
  1. Some settings must be enabled in Production resources (RESCONFIG) for WOO to be grouped. You can also enable the distribution of operation time to the grouped WOO. For more information, refer to Resources (RESCONFIG).

  2. Choose the desired resource. The work order operations in Status ST:2 and ST:3, which are not grouped are displayed.

  3. Select Add new group to create a new group. The group is named automatically in the format DD.MM.YYYY - Group N, for example 23.05.2020 - Group. The number after Group is based on a sequence which is reset on a daily basis.

  4. The list to the right is empty, because the group is new. Highlight the desired work orders in the left grid, or use the box in the top right column to choose all available, and select Assign to group.

  5. The list to the right is now populated with work orders, which can be run simultaneously by selecting Run group. The group is available for more additions in ST:1, and is set to ST:4 when the work order operations are started.

Resource Work Order Operations (RWOO)

The Resource Work Order Operations (RWOO) application is used to show the work orders related to a production resource, with all necessary details and links to related documents.

Work Order Operations filter:

This is a pre-made filter where you fill in any information you have regarding the work order operations you want to find using the filter fields. You can filter by serial number, work order number, product name, customer's reference number, operator and associated material. For some resources work order lists, it can be useful to filter the list by the material associated with the operation. An example is cutting operations where it may be wise to choose jobs that use the same material, because it leads to less setup time to switch the tool between jobs.The field 'Material name' can be used to filter jobs by material / part.

How to use the Resource Work Order Operations application
  1. Enter the name of a resource, or click the arrow to search, in the Production resource field.

  2. All work order operations for the resource will be shown in the list below.

From this list it is easy to check relevant information using the different links in the columns:

  • Work order: The link in this column sends you to the Production Work Order (PWO).

  • Product: The link in this column sends you to the Product (ART) document.

  • Operator: The link in this column sends you to the Personnel (PER) document for the user who is set as the operator for the work order operation. If the work order operation is not started, this field will be empty.

  • Columns with icons:

    • Production Status Info: This link sends you to the application for viewing the work order planning operations.

    • Confirm Picking: This link sends you to the PICK application where you can confirm the picking.

    • Scan Picking: This link sends you to the SCANPICK application where you can scan the picking with a handheld device.

  • Link column (last): This link will send you to the Work Order Operation (WOO) application where the operator can perform actions for the work order operation.

Work Order Distribution (WOD)

Distribute work order operations to resource members (DWOO) is an application used for distributing work order operations from resource groups to resource members.

The menu to the left shows the Production Work Orders (PWO) which can be selected and distributed to the available Resources (RES) listed to the right by clicking the button Assign to member. The work order with the active resource is then listed down right, in the Member resource work order operations.

The Todays Work Order Operations Progress Widget

Use the Todays Work Order Operations Progress widget to view the progress of daily planned Work Order Operations. The widget displays the daily Planned, Running and Completed operations. A bar chart that represents the daily Planned and Logged hours is also displayed.

To add the widget to your desktop.

  1. To add the Todays Work Order Operations Progress widget to your desktop, select in the desktop.

  2. in the Search field, enter TodaysWOOProgressWidget and select the ENTER key.

  3. Select TodaysWOOProgressWidget and select .

Structures management

A product structure can be defined as the content of a production, a combination of parts and operations, which is combined to produce goods.

This process may result in

  1. Creation of a new product structure.

  2. Modification of an existing product structure.

A product structure, or the content of the production, differs from product to product. But the same product may have different product structures. For example: One specific computer monitor consists of a certain type of parts and operations, while other monitors have different parts. Parts in this situation are motherboard, power supply and screen while operations are soldering, assembly and packaging. The monitor product may receive updates, where certain parts are changed for the better, while still being the original monitor product. This calls for a modification of the product structure.

Tasks related to this process

  1. Creating a new product structure

    The finished product and parts need to be structured into a product structure in the ERP system. Cost, time and price is defined.

  2. Adding attachments

    Attachments, such as drawings, instructions and other version-specific documents are connected to the structure.

  3. Approving the product structure

    After the product structure is created, it needs to be approved by an approver.

  4. Modifying product structure

    The finished product may be modified using the original as base.

Settings for Production - Structures management

Setting name

Description

Add Cost items to a structure

If setting is 'ON' - it enables the possibility to add additional cost items to structures.

Auto Revise Kit Parts

If setting is 'ON' - Auto-increment functionality for Class = K* parts is activated. If setting in 'OFF' - Manual update must be done

Product Change Verification

If setting is 'ON' - you can create Measurement document (MSR) to Verify the Product Structure (ARTKIT)

Create a new structure

  1. To open the Product (ART) application, find Product in the RamBase menu and then Product management. Click Products to enter the ART application.

  2. Click the Create ART icon to open the Create Article popup.

  3. In the popup:

    1. Enter part name.

    2. Enter text (optional).

    3. Select manufacturer (Mfr).

    4. Choose Class K.

    5. Choose relevant Production Data in the ProdLine field.

    6. Choose either Batch or Unit in the LcmDoc field.

    7. Choose the desired option in the SnowClaim field (Serial number claim). This determines any requirements for serial numbers on the reception and / or shipment of goods.

      1. IN: the serial number table must be updated for all incoming goods (SSA items) for that material/article.

      2. OUT: the serial number table must be updated for all shipment document items (CSA / SRT) for that material/article/product.

      3. PWO: the article/product will be added automatically to LCM Part List for productions where the ART is included in the structure.

    • Click the Submit button.

  4. Add the necessary information in the same way you would when creating a standard part. There is in addition a checkbox in the Purchase area where you can check if the Kit is an external production. Checking this will remove the Kit from Prodplan, as it is not a planned production, but in the Purchase (PUR) application as it is a procurement situation.

  5. Right click, or press F12, to open the action menu and set the article to the desired status.

  6. Press the KIT icon to the right of the Class field to enter KIT details and the designer.

  7. Here you may input the version name, Revision number and upload any drawing of the structure.

  8. Click the Designer tab.

The Designer contains two panes. The structure definition is always displayed in the left pane. The right pane is used to display parts from the ART-archive, or operations from the OPR archive. To switch archives, use the two icons in the header.

  1. Operations are added first, to have the structure in which articles and parts are added to be included in the structure.

  2. To add new parts to the structure, click a part icon and hold, then drag and drop it at the appropriate position in the structure definition (on the left).

  3. Click the Kit Details folder to start the Approval process.

  4. Click the Request Approval icon and the structure will receive ST:2.

  5. The approval will be sent to the approver who are defined as such. After approval, the structure will receive ST:3.

  6. To activate the structure, click the Activate Version Icon.

  7. A popup will be opened where you are given the option to update the production plan.

  8. Press Activate when you are done to finish the activation of the structure, and the structure will receive a valid status.

Creating special structures

Special structures can be created for a Sales Order (COA). Add customer and other mandatory information as you would normally have done making a new COA.

  1. When you add the desired product, you add the quantity and mandatory information and click the Create button.

  2. Double-click the item line to enter the COA item.

In the context menu, choose the option Create new or copy product structure to item.

In the popup, decide whether you want to create a special product structure from scratch, or you want to copy an existing structure/version from the Product (ART) application.

Copy standard structure from product

This option is used when you wish to modify an existing structure. You copy the existing structure you choose from the Product structure lookup field in the COA and make your modification to suit the desires of the customer.

Create new structure

This option creates a new empty structure where you may add articles and operations.

You can see the View Structure for sales order item icon in the item line. The Context menu option View standard structure is used to inspect the original standard structure. Clicking the Inspect special structure icon on the item line or the Context menu option View structure for sales order item, will bring you to the KITDOC window.

The special structure is now in ST:1. Now you may perform any desired modifications to the structure, such as add or replace operations or articles.

When the desired changes has been performed, press ESC twice to return to the COA document. Special structures do not need to be in ST:4 to be ready for sale, but the special structure needs to be released for production. Choose the Context menu option Release all items for production.

Versioning of structures

To create a new version of a structure, enter the kit you wish to create a new version for.

When the structure is done and ready for approval from the approver, click the Request Approval icon at the top. This will set the structure in ST:2.

The request will be sent to whoever is defined as approver of the structures in your company. The approver will then inspect the structure and approve. After approval the structure will receive ST:3. It is still possible to edit this by clicking the icon Open for Edit, which will send the structure back to ST:1.

The last step in the process is to activate the structure which is performed by clicking the icon Activate Version. You will then be asked in a popup if there is a need to update production plan. Choosing YES will update all non-started productions containing the previous kit version.

The planning process

Planning, or resource planning, is a process to get the optimal use of the resource capacity and to deliver the product before deadline.

This process may result in

  1. The needs of production is identified.

  2. The needs of production is collated.

  3. The production order is registered.

If a production company does not produce goods itself, most production orders will be initiated by a customer order. This means that the sales department, which receives the customer order, need to hand the planning process over to a production planner, before terms can be agreed upon.

A planning process such as this involves the identification, categorization and prioritization of a production need in sequence. This prioritization books resources such as machines, personnel and any external resources. Planned delivery is then communicated back to the sales department.

This planning phase may also result in several customer orders for the same product to be combined and produced in the same production run. This enables the production company to save production costs and delver at an earlier date.

Tasks relevant for this process

  1. Creating a new production order

    Production need is identified through customer orders or orders from the warehouse manager.

  2. Planning production orders

    The production order is planned through prioritization, time usage and cost price vs. sales price.

  3. Preparing production orders for production

    Production orders ready to start must be ordered by releasing it for the involved resources.

Settings for Production- Planning

Setting name

Description

Automatically link Products (ART) with Product Structure to Pending

If setting is 'ON' - Sales Order items with Class=K* will be automatically be set to Pending by the program.

AutoSync PlanningOperation with WorkOrderOperation

Default Production Lead time

Value in this setting is used as Default Lead time, - if no leadtime is set on the Product (ART). To be used in production calculation.

Default view in Resource WorkOrders folder

Value in this setting could be one of these alternatives: READY - Resource WorkOrders folder is filtered on ready Production Work Orders (Operation  in Status=3). ACTIVE- Filter on ready and running Production Work Orders (Operation in Status=3 and 5). ALL - Showing all Production Work Order. If setting is not activated, default will be 'ACTIVE' -  ready and running (Operation status=3 and 5)

Pending by Minimum Stock folder in PRODPLAN

If setting is 'ON' - the folder 'Pending by Minimum Stock' will be available in PRODPLAN, and thereby the possibility to see production needs based on the Product setting for minimum stock - ReorderQuantity and ReorderPoint on Product (ART)

Production Customer Forecasting

If setting is 'ON' - The functionality that will allow company to use Customer Forecasting in Production module is activated.

NOTE: Forecast functionality is not ready for use in Rambase

Production Work Order (PWO) - Assign To Stock

If this setting is 'ON' - the users have the option to start a job that try to link all items in the production work order to stock. In case there is no free stock, the program will try to swap links with other documents. The job is started by the option Assign To Stock.

Set Confirmed Date on change of Prodend in a Production Work Order

If this setting is 'ON' - The Confirmed Date (ProdConf) is updated and set when changing the production start or end date.

The Resource free capacity is limited

Value in this setting is a percentage that will impact the Resource available shown in the Resource Planner. If resource day load is less than the percentage set in this value, the resource day 'bar' is shown in green colour at the resource planner overview. Colour shown yellow if load exceeds this percentage

The Resource free capacity is low

Value in this setting is a percentage that will impact Resource available shown in the Resource Planner. If resource day load is exceeds the percentage set in this value, the resource day 'bar' is shown in red colour at the resource planner overview

Time resolution for production calendars

Value in this setting is the Time resolution for production calendars. Example: 00:15 allows calendar shift start and end time to be hh:15,hh:30,hh:45,hh:00. Default resolution if setting is deactivated is '00:30'

Use PLO Archive For Planning

This setting will be used temporary by the JHC development team to allow old and new code during the implementaion phase, replacing ALM with PLO for planning purposes.

Use Assignment Window for Production Work Order (PWO)

If both this setting and 'Margin for SalesLeadTime Assignment Window' is turned "ON", Production Work Orders will always get assignment from PENDING if LINKDELDATE in SAR is outside of the period given by SALESLEADTIME from ART plus the value from the setting 'Margin for SalesLeadTime Assignment Window'. The SAR optimize process will only re-assign production work orders inside of this window. In case several companies have common ART and SAR registers (Group Structure), 'Margin for SalesLeadTime Assignment Window' should only be set up for the company that is set up as OWNERDB, while 'Use Assignment Window for Production Order' should be set for each one of the sales databases.

Warning for Shipping to Supplier on External Operations

Value in this setting is how many days before warning is displayed in the column "ShiptoSupDate" for shipping to External Work. If the setting is 'OFF' - the "External Operations" folder in ProdPlan will not show.

Production Planning (PRODPLAN)

Production Planning (PRODPLAN) is a planning tool used to create Production Work Orders (PWO), and manage the forthcoming production needs.

To open the Production Planning (PRODPLAN) application, find Production in the RamBase menu and then Planning. Click Production planner to enter the PRODPLAN application.

To inspect your company's production needs, you can see this in the Pending Orders by Part folder. The Qty column shows the quantity of the part in the item line waiting to be produced.

Pending by minimum stock

Pending by Minimum Stock in the Production planning application (PRODPLAN) gives the required minimum stock of the article required for daily operations. If the stock is below this given quantity, it is shown in Pending by Minimum Stock.

Setting the minimum stock
  1. The minimum stock is set on the article representing the material or part. To open the Product (ART) application, select Product > Product management > Products in the RamBase menu. The Stock and Free columns give the current stock and the quantity available for use.

  2. In Local Stock, select Create New in the left hand corner. A popup appears, where you can specify the following:

    1. Location. Specify the desired location of the stock.

    2. Purchase group. Specify the purchase group.

    3. MinStock. Enter the minimum stock. If the stock quantity is lower than this number, a purchase or production requirement is created.

    4. StockLoc. The internal location of the goods.

    5. ReorderQty. Enter the quantity to reorder if the current stock is less than the minimum stock. This field is for information only.

  3. Pending by minimum Stock in PRODPLAN gives the products where there is a shortage. Only products with a specified minimum quantity are shown here.

  4. Select the Enter key to open the production order. The quantity shown in Qty in the Production Work Order (PWO) is comprised of the minimum stock quantity. This field is editable, so you can update it according to the reorder quantity given for the selected product (from the ART application).

  5. After you select Create Production, the entry in Pending Minimum Stock is not displayed.

Note

If you have active production orders to complete in future, for articles with a specified shortage quantity, the free quantity is affected by this in the way that the future productions fill the current shortage. If you have shortage, but RamBase does not show a purchase requirement in the Purchase (PUR) application, check if there are any production orders that make up for the shortage in the future.

Create production for order

  1. To open the Production Planning (PRODPLAN) application, find Production in the RamBase menu and then Planning. Click Production planner to enter the PRODPLAN application.

  2. Find the kit which you wish to start production for, highlight the item line and press ENTER.

  3. Enter the Pending by Order folder to see all the pending orders for this kit.

  4. Check the boxes in the select column for the orders you wish to start.

  5. After your selection is finished, click the Create Production button at the bottom.

  6. This will create a Production Work Order (PWO) for the selected quantity of kits to be produced.

  7. Inspect the information to ensure everything is correct.

  8. Click the Confirm Production button at the bottom when you are ready to confirm the production.

Distribute work order operations to resource members (DWOO)

Distribute work order operations to resource members (DWOO) is an application used for distributing work order operations from resource groups to resource members.

The menu to the left shows the work order operations which can be selected and distributed to an available Resource member (RES) listed to the right by clicking the button Assign to member. The work order operations for the member resources are listed down right, in the Member resource work order operations grid.

Production Work Order (PWO)

A Production Work Order (PWO) is a request to produce one or more pieces or units of a certain product. Products may be produced for stock, or according to a specific customer order document (COA).

The PWO application contains information about production orders and is managed by the PRODPLAN application. PWOs are listed in the Productions folder.

To open the Production Planning (PRODPLAN) application, find Production in the RamBase menu and then Planning. Click Production planner to enter the PRODPLAN application.

To view details about a specific production order, click the DocId link or highlight a line in the Production Menu window and press ENTER.

The Production Order window will appear.

The icons to the right, in the Part-box, indicates the different elements to be inspected. These icons enables you to inspect the status and details of the structure, stock and purchase orders. They also indicate in which current state the PWO is in and gives you the opportunity to cancel or approve.

Create Production Work Order (PWO)

Creating a production not connected to an order, but when you need to increase the stock, you can start from the Productions folder in the Production Planning (PRODPLAN) application.

To open the Production Planning (PRODPLAN) application, find Production in the RamBase menu and then Planning. Click Production planner to enter the PRODPLAN application.

You can also type PWO into the program field and press ENTER to go directly to the production folder.

  1. Click the icon Create PWOCREATE to create a new PWO.

  2. Choose the kit you want to produce in the Part field.

  3. Choose the desired completion date in the Req field using the calendar icon.

  4. Choose the desired quantity of the kit in the Qty field and click the Create New PWO button.

  5. Inspect the information and edit if needed.

  6. Click Confirm Production when finished.

  7. The PWO is now in ST:2. There is a negative material trend, which means there are no goods in stock to produce the kit.

  8. Press F12 to open the action menu and choose the option Release for Purchase. This may be reversed with the F12 option Block for Purchase.

  9. Use the magnifying glass icon to the right to inspect links to stock and purchase orders. This is a list of all the articles used in the kit.

  10. If there is a need to procure certain articles to produce the kit, this may be done using the PENDING link under the column Linked To. Highlighting the item line in question and pressing ENTER will send you to the purchasing program where you may make a purchase order for the article in question.

    • NOTE: If this is a high priority production, and the parts needed are linked to other productions, you can use the action menu option Assign to Stock, which will re-link the needed parts to this production. This is not possible if the parts have been locked, if the target production is in edit mode, or the picklist has been printed. This function is only available if it has been activated in the settings.

  11. When all the articles needed for the first operation of the production has been procured, it will move to ST:3 and the PWO may be released for production. Click the button Release for Production at the bottom of the window.

    • The usual way of handling purchase requirements is using the Purchase (PUR) application.

  12. The PWO will now receive ST:5 and a Life Cycle Management (LCM) document will be created.

AutoCreate the Production work orders (PWO) for sub-structures

There are some products and Production work order (PWO) processes where it is advantageous, or even necessary that the PWO for the sub-products are created automatically when you register the main PWO for the top-level product.

This normally applies to PWO that are created for Customer order items (COA) having their own structure, either created from scratch or as a copy from one of the product structure versions. These COA structures are known in RamBase as Customer order-specific structures. The structure be modified in all levels for the COA item and the result is copied to the PWO created for the COA item.

You can control the sub levels for which the AutoCreate applies, also for the structures specific to the customer order. This is based on the fact that the specific or modified structure very often only applies to the top level, and that some of the sub products are standard products that are used by several top products, and therefore normally are produced to stock.

Functional description for AutoCreate sub production work order

Standard product structures

The setup for the preferred autocreate level is done in the main product structure and its sub product structures. The field AutoCreateSubProduction at the sub product line in the bill of material (BOM) is used to specify if the sub production PWO shall be created by the system when the products PWO is registered.

See the example below of one top product with sub products, the products KIT has three sub products.

There will be created PWO for item 1 (393Sub2) and for item 3 (233sub1) when the PWO for the top product is registered. The program will also look into the next level (subs) within these two subs and check if there are ‘sub-subs’ with autocreate set and create PWO for these.The item 2 (393Sub1) will in this case not have any PWO created, and the function does then naturally not go deeper into that branch. The PWO must be created by manual tools (PRODPLAN) and when that PWO is registered there might be created PWO for branches in that BOM.

Customer order-specific structure

When the function ‘Create new or copy product structure to item’ is used at a customer quote item (CQU) or a customer sales order item (COA), and copy is selected, the complete product structure with all branches and all levels is copied to the item. The item has a complete order-specific product structure. The autocreate setup in the product structure and its branches is copied to the item structure.This means that PWO are only created according to the autocreate setup also for this item-specific structure when the top PWO is created for the COA item. The program will not create a PWO for a sub that has AutoCreateSubProduction set to No, and will not look into that subs potential ‘sub-subs’. This sub and its ‘sub-subs’ will be handled as need for standard products, and will search for available stock or, KIT or Partother supplies to cover for the needed quantity.So if a sub or ‘sub-sub’ is changed within the order specific structure by adding/replacing/removing parts or operations and this is supposed to be transferred to production: The user must ensure that the AutoCreateSubProduction = 1 (on) at the required levels of the branch, all the way from the top level.The AutoCreateSubProduction can be set / cleared at all sub products by selecting the Enter key after selecting the item in the BOM. The user-specified setup is transferred from CQUto COA to PWO.

To autocreate the PWO for sub structures,

  • In the Article application, ART, select Misc and set AutoCreateSubProduction to Yes. The PWO are created even if there is exisiting stock of that product, article, KIT or Part. This setting must be enabled on every level that you require autocreation of a PWO for its sub level. If the setting is not enabled on a specific sub-level, PWO are not created for any of the sub-sublevels below it.

Planned operations for Production work order (PWOPLO)

The PWOPLO application allows you to inspect and change Planned operations for the Production work orders.

  1. Enter PWOPLO/PWO number, in the Program field and select the Enter key to open PWOPLO, where PWO number is the number of the PWO. For example if the PWO number is 118384 enter PWOPLO/118384 in the Program field.

    You can also open PWOPLO from the following applications:

    1. PRODPLAN

    2. PWO

    3. ITMPWOINSPECT

    4. PWOTREEVIEW

    5. RWOO

You can view the following information in PWOPLO.

  1. Status. This column shows the status of the Production work order PWO.

  2. State. This column shows the extended status information based on the state of the planned operation and the corresponding work order operation and production work order.

  3. Op no, the Operation number for the operation in the PWO.

  4. Resource Name is the name of the resource or resource group that is assigned to the operation in the PWO. Select at the right side of the Resource Name to view the resource in the RESCONFIG application.

  5. Tasklist. Shows the list of tasks for the resource, Select at the right side of the Tasklist number to view all the tasks assigned to the resource in the RWOO application. If the resource is a resorce group, DWOO opens, where you can distribute tasks between resource group members.

  6. Operation shows you the name of the planned operation.

  7. Planned shows you the time in hours assigned for the operation in the plan. Hover over the Planned hours to open a popup that gives you the breakup of the Planned hours as Setup, Processing and Cleanup.

  8. Logged shows you the time in hours used for the operation in the plan. Hover over the Logged hours to open a popup that gives you the breakup of the Logged hours as Setup, Processing and Cleanup.

  9. Remaining shows you the assigned hours remaining after the logged hours are reduced using the formula Planned-Logged hours = Remaining hours.

  10. Man hours shows you additional man hours consumed in production.

  11. Time deviation gives the deviation as a percentage according to the formula (Accrued hours-Planned hours) * 100/Planned hours.

  12. Critical Date Critical date is a latest possible start date of the operation to complete it by the planned end date.

  13. Estimated end gives the estimated end date of production.

  14. Delay gives the difference between the planned and Estimated end of the operation.

  15. Worklog. Select to view the Work Order Operation Time Log, where you can see the details of Planned and Logged hours. You can also see the Man hours here, if any.

  16. Icon shows an icon that indicates the status of the production operation, if it is delayed or completed.

The right pane in PWOPLO shows the following.

  1. Planned start at. You can change the planned start here if the operation has not yet started.

  2. Planned finished at. You can view the planned completion date here.

  3. You can also see other planned time components for production operations such as Setup time, Run Time, Wait time and Cleanup time.

  4. Source gives the details of the source PWO. Select to open the PWO pplication.

  5. Quantity gives the quantity of the Parts or Kits in the Production operation.

  6. Part gives the name of the part or kit that is used in the planned operation. Select to view the part in the Article (ART) application.

  7. Planner shows the name of the person that made the plan for the operation. Select to view the person's details in the PER application.

  8. States shows the following read-only checkboxes.

    1. Priority which is a flag that indicates if Work Order Operation has been prioritized.

    2. Line production is selected if this product is planned and manufactured in line production.

    3. Operation locked is selected if the operation is locked, and must not be moved. Can be due to inspection by external source.

  9. States shows the following read-only checkboxes.

    1. Pending External Planner. This checkbox is selected if the plan is Is transferred to RPLAN and the operation is waiting for an update from RPLAN. This does only apply if the setting Wait for external planner to start operation is enabled. PWO with one or more operations with this flag on can not be released for production unless the flag is set to 0 for the operations in the PWOCRITICALDATE (operations list) application in the PWO.

    2. Changed . This checkbox is selected if the plan has been changed in RPLAN and pending an update in the worklist (WOO).

  10. Planned by day gives the planned daily Work time (hours), Load and Capacity for the resource.

Production Work Order Status - Distribution

The Production Work Order (PWO) Status - Distribution widget displays the frequency of the various statuses for production work orders in a color-coded donut chart. You can see the number of occurrences of every status.

To add the widget to your desktop.

  1. In the Rambase desktop, click Add widget.

  2. Enter production work order status in the search field and select the Enter key.

  3. Select ProductionWorkOrderStatusWidget to highlight it and select Add.

To view the Production Work orders with similar status.

  • Click any section in the donut chart. The Production Planning window opens. The PWO with status corresponding to the section you clicked are displayed in the Productions tab.

The Gantt Planner Tool (RPLAN)

RPLAN is a tool that you use to see a comprehensive visual presentation of the production plan and the resource load. You can drag activities and tasks to change the plan.

Several users with permissions can make changes to the same plan, so the users must decide the protocol for making changes to plans. Rambase or RPLAN do not manage or control multiple versions of the plan.

Product licensing and access control

RPLAN is licensed from a third party vendor, Netronic Software.  The tool is used as an add-in to RamBase. The license is based on a monthly subscription for the RamBase customer with an unlimited number of users. RamBase (JHC) manages access to the tool in the near term. When a customer is given access, a RamBase partner manages the user access. 

If you have permission to view planned operations and make changes in RPLAN, you can view and update the plan in RamBase. If you do not have permission to update planned operations, you will see an error message and cannot update the plan.

Read permission

ViewPlannedOperations

Task:    Run RPLAN

Role :    Run RPLAN

Update permission

UpdatePlannedOperations

Task: Plan production work orders

Role:    Production planner

Features

The key features of RPLAN are:

  • When you open RPLAN, data is loaded directly from the resources, the work orders and the associated operations.

  • View plan by resources, planned jobs and load (resource load).

  • Drag to move jobs along the timeline. or between resources.

  • RamBase does not automatically save the changes you make in RPLAN. You can decide whether to save the changes.

  • Various colors denote the various statuses, similar to the status colors in Rambase.

  • Overloaded resources are indicated by a warning icon.

  • Detailed information about jobs and work orders.

  • Shows connections (constraints) between the jobs for a work order.

  • High priority job marking.

  • Scroll functions to move horizontally in time and to scale the view per day/week up and down.

Save your changes to RamBase

  1. Select Save changes to RamBase.

    Your changes are committed to the corresponding planned operations (PLO) in RamBase and the flag IsChangedByPlanner is set to 1 in these PLO. There are two options to commit the changes to the work order operations (WOO) and subsequently the job list for the resources (RWOO):

    1. The company setting AutoSync Planning Operation with Work Order Operation is set to ON: The WOO is updated automatically by changing the corresponding PLO.

    2. The autosync is set to OFF: Use PRODPLANSYNC and update the work order operations by command.

    To discard your changes, close RPLAN or select Reload Data.

Use RPLAN

  • To start RPLAN, Enter RPLAN in the Program field and select the Enter key.

Resource view resources and planned jobs

When you open RPLAN, the Resource View is displayed by default. The resources and resource groups are shown on the left and the planned operations (PLO) are shown as bars in the grid. The assigned resource or resource groups are shown along with the plan timelines. The work order (PWO) number is shown in the bar, and the color of the bar indicates the status of the task.

  • Purple - the task is active.

  • Blue - the task is ready to start.

  • Gray - the task in waiting on some pending action.

  • White - the work order is not released for production

Mouse scroll functions

Use the mouse scroll wheel to access various functions in RPLAN.

  1. Place the cursor in the grid and scroll up or down to scroll through the resources and production tasks.

  2. Place the cursor in the grid and select shift to scroll the timeline in either direction.

  3. Double-click the timeline bar and scroll to scale the display from days to weeks or hours and minutes.

  4. Drag the timeline in either direction to advance the timeline or go back.

View more Information on production tasks

Every bar in the grid represents one planned operation (PLO). Do the following to get more information about the operations and the work orders.

  1. Hover over a bar to see the work order number, operation status, start and end time.

  2. Click the bar to see connections to other operations for the work order.

  3. Double-click the bar to see more information about the work order and operation such as the Delivery date from the work order, accrued time and actual start date and time. The real start date and time is shown in the planner view for operations that have commenced.

High priority production tasks

High priority PLO are indicated by a yellow dot in the upper right corner of the bar.

Change the plan by moving production tasks

You can move the production taks in three ways.

  1. Change the start date and time for one task. Drag the bar horizontally to the necessary start date and time. The accuracy of the new start time depends on the selected granularity of the timeline. If the scale of the timeline is in minutes, the start time can be set more accurately by dragging, than if the scale of the timeline was in months. The rules for changing production tasks by dragging are as follows.

    1. You can overlap production tasks.

    2. You cannot move production tasks that have commenced, which are indicated by purple bars,

  2. Assign the production task to another resource. A production task can be assigned from the resource group to one of the members of that group or from one member to another. Drag the production task to the necessary resource.

  3. Select several jobs for moving to a new start time or to another resource group member. Ctrl + click the necessary task bars and right click them to select the necessary action. You can move the selected production tasks by x number of days or assign them to a different resource.

Setup move mode

  1. The Move mode setting must be enabled. Enter CSV in the Program field and select the Enter key.

  2. Set the Move mode for Operation Planner to ON. There are three options in the list, select the necessary option.

    1. MINIMAL: Only move this planned operation (PLO) element, do not touch the remaining operations, unless this element is moved in front of/after an adjacent operation, in which case the affected operations are moved according to the rules of PACK.

    2. SINGLE: Only move this planned operation (PLO) element, fail if moved across prev/next.

    3. SIMPLE: Only move this planned operation (PLO) element, do not touch the remaining operations, don't care about conflict. Even possible to move started Operations or move them to before SYS.DATE/TIME.

External operations for external resources

External operations that are not yet purchased, unlinked to an SPO and/or SOA, can now be moved in the planner. External operations that have been purchased, indicated by in the bar, cannot be moved.

  • To change external operations, change the purchase order, then reconfirm the purchase order.

Resource load warning

You can see a warning icon, a yellow triangle on the left of resources that have more assigned work than available capacity for one or more days.

  1. Select at the right of the resource to Inspect the load.

  2. Select the red load bar to see a pie chart of the planned tasks and hours assigned.

Load view – resource load by date

The load view shows the resources, capacity and load per day.

The bars in the load view are color-coded as follows:

  1. A white bar represents the capacity in hours per calendar shift for the day.

  2. A green bar indicates the load per day when the load is within the available capacity.

  3. A red bar indicates the resource load exceeds the assigned hours for that date.

Select any bar to see a pie chart of the planned tasks and hours assigned.

Filters

Resource filter

  • Use the resource filter to limit the view to selected resources, Select one or more resources or resource groups to view.

Customer and customer order filter

  • Select a customer in the Customer list, which shows only customers related to open work orders. The view is limited to work orders (main and subs) for the selected customer and the bars applicable to other customers appear dimmed. Select the Customer order (COA) number in Order lookup to limit the view to only work orders related to one specific customer order item.

  • A production work order (PWO) or a work order operation that is set on hold is indicated by on one or more bars.

Handling paused operations

Work order operations that are currently paused are indicated by in RPLAN.

When you double-click the operation bar shown above, a window appears, to inform you that the operation has been rescheduled . The paused plan window is shown below.

Rescheduled (paused) operations are put on the plan according to the planned start date. If the operation has commenced again, the actual start time is used and displayed. The plan may have to be reloaded in RPLAN to use the actual start time as shown in the window below.

Change the start and end date/time in the operation

You can change the start and end time of an operation by right clicking on the associated bar, and selecting force start and end time.

You can manually change the given periods. You must change both the start and end time before the changes can be saved.

Planned start and end dates are changed in RamBase only after the changes are saved in RPLAN. This function is only available for operations which are not active.

Recalculate all operations for a resource

You can recalculate the planned operations according to the current capacity of a given resource.

  1. You must select a specific resource by using the left mouse button. Select multiple resources with Ctrl + left click.

  2. Right click on your selection and select Recalculate resource.

Every operation is calculated separately to comply with the current resource calendar, while maintaining the original start date. If some operations cannot be modified for any reason, RamBase notifies you.

After the resource recalculation, you must save the changes to RamBase.

Product and quantity information for a selected operation

The popup window for the selected operation now displays information about the quantity and the product that will be manufactured under the production order.

Production resource capacity and load (RCL)

The Production resource capacity and load (RCL) application is a production resource capacity and load visualization tool. You can view the daily load for various resources and resource groups. The resource load is displayed as a percentage based on the following calculation (Assigned hours / Capacity Hours * 100). The RCL tool only displays data, you cannot change the data.

The load icons are color-coded. Green indicates the load is within allowable limits, yellow indicates the load is in warning state, red indicates the load is in the error state. You can set the allowable limits, warning and error thresholds.

Settings for RCL

  1. To set the allowable limits, warning and error thresholds enter CSV in the program field and select the Enter key.

  2. Navigate to the settings in Production > Planning.

  3. Enable the setting The Resource free capacity is limited and enter the warning percentage value for the resource daily load in the field. If the resource daily load is less than the percentage set in this value, the resource day icon is shown in green color in the resource planner overview. The color is yellow if the the load exceeds this percentage.

  4. Enable the setting The Resource free capacity is low and enter the error percentage value for the resource daily load in the field. If the resource daily load is less than the percentage set in this value, the resource day icon is shown in yellow in the resource planner overview. The color is red if the the load exceeds this percentage.

  1. To open RCL, enter RCL in the Program field and select the Enter key.

  2. To filter the results by production resource, enter the name of the resource in the Filter by production resource name field and select the Enter Key.

  3. You can view the resource capability and load by date. The assigned hours and capacity are given as values below the progress bars. The progress bars visualize the loads as percentages. Select or on the left and right sides of the date field to go back or advance the date. You can also select to open the calendar app to select the necessary date, or enter the date in the date field in the yyyy.mm.dd format.

  4. Select From Today to see the resource capacity and load from the current date. The tool shows resource capacity and load for four weeks forward from the current date.

  5. Select any load icon by double-clicking to view a pie chart and the following data for the resource or resource group.

    1. Capacity hours

    2. Available hours

    3. Assigned hours

    4. Assigned to active work orders

    5. Assigned to planned work orders

    6. Resource load as percentage

  6. Production resources are categorized into resource groups, Select in the Id column to expand the resource group and see the resources.

The Planned Resources Capacity Utilization Widget

The Planned Resources Capacity Utilization widget shows you the history of utilization of planned resource capacity as a line chart. This widget is useful to get a quick history of the utilization of the planned resources. The Y-axis shows the utilization as a percentage of the total available capacity. The X-axis shows the time interval in months.

In the gray areas at the top of the widget, the planned and accrued percentage utilization is shown for the Year to Date (YTD), which is from 1st January of the current year to the current date. The planned and accrued percentage utilization is also shown for the current and previous months.

  1. To add the widget to your desktop, select in the desktop.

  2. Select ResourceCapacityUtilization and select .

  3. Select the Chart type to view the chart as either a Fluctuating line, Accumultaed line, or Bar chart.

Delivery Project (PRO)

Delivery project is a RamBase-tool that give you status and overview of cost/man-hours and revenue on selected sales orders. Once you have collected one or more sales orders on a project, you will see the total resource usage and can check that the cost does not exceed the budget or the plan.

Functionality
  1. Create a delivery project and tag a selection of sales orders from the same customer.

  2. Use the snapshot for status overview and cost control

  3. Visualize the status with charts.

  4. Add milestone to the reports

  5. Use completed % to calculate accrued income.

  6. Export reports to Excel

Limitations

The tool is limited to cost and revenue directly assigned to the sales order items. It is not possible to add extra cost like purchased services that is not linked to a sales order item. The work breakdown structure (WBS) list in the snapshot is a fixed structure related to the article. The most detailed overview comes from articles with a structure (class K or KA).

How to start the process

The “Delivery Project”-tool starts by enter PRO in the program field in RamBase. The screen is divided into two spaces:

To the left: Delivery project overview

To the right: Reports and orders connected to the highlighted delivery project

  1. Create a new delivery project using the Create new project-button in the lower left corner. Select the customer and give the delivery project a name.

  2. Attach a sales order, or several, by opening the Orders folder and clicking the Add order to project-button at the bottom.

  3. Click the Activate project-button in the action menu to activate the project

Overview of tabs in the right area of the screen

Snapshot

Once a day, RamBase creates a snapshot of the delivery project. Just find the snapshot tab in the right side of the screen.

This gives you a day by day overview of your delivery project:

Note: If the delivery project has low activity, the snapshot will just show on days with changes.

Details in the snapshot

Snapshots can be made at any time if the delivery project is active by using the button in the upper right part of the screen. It will run automatically every night and present a new snapshot if there are changes since the last snapshot.

Choose the tab “Snapshots” in the right area of the screen.

At the right end of the highlighted item – click on the arrow-link as highlighted in the figure above.

This leads to the “delivery project snapshot” screen.

Functionality in snapshot view:

Snapshot header:

Milestone – free text field – appears in snapshot overview on main page.

Completed % - Manual review – will overwrite the calculated field “Accrued Income”.

WBS list

Numbers 1-4: The default view when opening a PROSS is that the WBS lists all levels from the included scopes.

  1. 1 – only show first level of each scope.

  2. 2 – only show two levels of each scope.

  3. 3 – only show three levels of each scope.

  4. 4 – show all levels for each scope.

    Export to excel: Get the number from the snapshot screen copied to an Excel-sheet. This function will only export the selected columns.

    Expand WBS list: It possible to expand and collapse the WBS list using the small arrows in the WBS-list. (WBS = work breakdown structure)

    Comp % related to calculated “Accrued income” in snapshot header. Inherits the value from last snapshot

    Link to documents: By following our small icons and you can follow the link to a sales order, production order or the product structure.Column view templates

    Columns are selected (and column selection view is closed) by the - icon in the WBS list header.

    ‘default view’ is the default, but the user can also now create own templates by:

    - Open column selection and choose columns.

    - Use at the bottom of the column list to add a personal template, give it a name and save by the ‘v’: .

    - The new template is showing at the top of the column selection as ‘Current view’, and all personal templates are selectable.  The last used template is default when entering a PROSS view.

    Orders

    This tab gives you an overview over sales orders connected to the delivery project. If the project is in status 4 or lower, you can add or remove sales orders.

    The delivery project can only be related to one customer.

    You must add the total order, not just one or some items.

    Billing

    The billing tab will show all the invoices connected to the delivery project. Also from an Invoice Plan (CIP) or a Sales Credit Note (CCN).

    Chart

    Check out the chart function where you can visualize the delivery project.

    WIDGETS

    Also, check out our new project delivery widgets.

    Assign to stock

    The Assign to Stock functionality is useful when you want to release a production, since this requires that all parts used in the first operation must be assigned to stock.

    When you create a Production Work Order (PWO), the parts needed for the production will be assigned to goods in stock (SSA), to goods produced by another production (PWO), to a Purchase Order (SPO/SOA) or to a pending purchase (PENDING).

    The Assign to Stock functionality will take all the assignments that are not assigned to and try and assign them to stock. If no goods are available in stock the program will try and swap assignments with other production work orders and sales orders which are assigned to stock. If no swapping can be performed the old assignment is kept.

    Criterias for assignments that can be assigned to stock
    1. Is not assigned to stock

    2. Must be a physical part

    3. Not locked

    4. Not initialized for picking        

    Criterias for assignments that can be swapped with
    1. Same part

    2. Same location

    3. Must be assigned to stock

    4. Must be a physical part

    5. Not allowed for goods owned by other customers

    6. Not locked

    7. Not initialized for picking

    The setting Production WorkOrder Assign To Stock must be activated.

    Assign to Stock functionality is also available for sales orders. The setting Sales Order Assign To Stock must be activated.

    Partial delivery on external work

    To deliver selected products (partial delivery) for external work, use the following procedure:

    1. To open the Production Planning (PRODPLAN) application, find Production in the RamBase menu and then Planning. Click Production planner to enter the PRODPLAN application.

    2. Click the External Operations folder.

    3. Find the line you want to partly deliver and click the External Work Logistics icon on the right side.

    4. Click the Create SRT for SPO/xxxxxx-x icon to open the External Work: Create Shipping Document popup.

    5. Click the Create SRT button next to the Create SRT for PWO/xxxxxx-x to partly deliver the SPO.

      • Note! It is also possible to create SRT for the whole SPO in the popup.

    Production

    Link to interaction

    A production is the process where something is produced using resources and operations.

    This process may result in

    1. Finished produced product.

    2. Modified product.

    3. Scrapped product.

    There are several phases one needs to take into consideration during a production. Resources and operations need to be prepared, such as warming up machines, programming machines or maintaining them. Another situation may be workers who need to read instruction manuals, drawings or other relevant documentation.

    The production phase is also divided into different steps. If you need raw materials for a production, these needs to be picked from the warehouse, for example circuit boards, screws, frames and other necessities need to be picked to produce a computer screen. Every step is logged into the system to keep track of the production process. Another important step is to log all used hours during the production, including picking, measuring, quality testing and other actions. In our example, a computer screen needs to be checked for picture and color quality.

    This, together with the cost of goods, will create an overview of the total cost of the product. The combination of raw material costs, worked hours and profit margin will then create the base for sales price, modification or scrapping.

    Tasks relevant for this process

    1. Pick job

      There will most likely be several production orders waiting for the same resource. The jobs are the set in a priority queue and picked by certain criteria.

    2. Logging work hours

      Work hours used per operation or per production order needs to be registered.

    3. Confirming picking from warehouse

      Goods to be included in the production needs to be picked from warehouse, and the production operator needs to confirm the pick.

    4. Performing testing and quality check

      Produced goods needs to be tested and quality checked to ensure they are ready for delivery.

    5. Finishing production

      After the produced goods have been tested and marked as ready for delivery, it needs to be freed and marked done.

    Settings for Production- Production

    Setting name

    Description

    Activate the use of Measurement Standards

    If setting is 'ON' - functionality for using Measurement Standards is activated

    Adjusting Production Total Cost

    Value in this setting is a CST reference with COSTTYPE=FIXED and CostAmount= 0. Used as Default Cost Element for Adjusting Total Cost on a Production Goods Reception (SSA). Format to be used: CST/NNNNNN (N for numbers)

    Automatically cancel SubOrders in Production

    If setting is 'ON' - All subproductions will be canceled when cancelling the main Production Work Order.

    Automatically split sub orders when splitting main Production Work Order (PWO)

    If setting is 'On' - Sub orders are split according to the split done on the top level of the Production Work Order (PWO)

    Block for production on Sales Order (COA)

    If setting is 'ON' - Sales Order items (COA-ITM) for Class=K* products will get

    =1.  Un-check "Block for production" on item to release Sales Order item to ProdPlan for creating Production Work Order (PWO)

    Block purchase on Production Work Orders (PWO)

    If this setting is 'ON' -Default will be blocking on new Production Work Order (PWO) from purchase. Production Work Order item will contain value '1' in the field ISBLOCKEDFORPURCHASE. Text is also showing at Production Work Order. Use F12 - 'Release for purchase' to allow purchase to handle the Production Work Order.

    Close Work Order Operation when operation is completed

    If setting is 'ON' - Closes the WorkOrder Operation  application (WOO) when operation is stamped as completed

    CloseWorkOrderOperationOnStartPause

    If On:

    Will close the WOO application when START/CONTINUE or PAUSE buttons are pushed.

    Default cost element for part change on Rework

    If setting is 'ON' - Negative cost is added when a part change is perfomed on a Rework process.

    Default Production Calendar

    Value in this setting is the Default production calendar that must exist if the production module is to be used. The Production calender has to be created from Company (COM) / Settings / Config Applications, by Add Program and choose PRODCALENDAR. The PCA reference to get, has to be added as value in this setting. Format to be used: PCA/NNNNNN (N for numbers)

    Default Step Between Operations when building a product structure

    Value in this setting is the Default step between operations when building product structure. '10': First Production Operation (OPR) gets OpNo=10, next gets OpNo=20

    Default Supplier when performing a Rework

    Value in this setting is a default Supplier (SUP) for creating Purchase Order (SPO) for part change on LifeCycle (LCM) where product is purchased externaly and not produced on a Production Work Order (PWO)

    Disable 'Forward To Stock' button on Production Orders

    If setting is 'ON' - Disables the 'Forward to stock' button at Productions (PWO) in st=8 (completed). Option to put products to stock is then to use the GIN program.

    DismantleSupplierAccount

    Dismantle Supplier Account

    Exclude WorkOrder print for Products with specific values in the field GR1

    If this setting is 'ON' - WorkOrder for PWOs with the specified values in the GR1 field on Products will not be printed

    Goods Transfer (STW)

    If this setting is 'ON' - Goods Transfer (STW) can be used for this company. If setting is 'OFF' - Goods Transfer cannot be used for this company. Goods Transfer is used to transfer goods from one location (LOC) to another location in RamBase.

    Link off Parts when part change on LifeCycle (LCM) that are not picked

    If setting is 'On' - Allows you to "steal" parts when performing a part change on the LifeCycle (LCM)document even if GoodsReception (SSA) has no free quantity. This can only be done from orders where parts haven't been picked

    Not Close Operations Log On Start Or Pause

    If setting is 'ON- Will not close the  APP/RESLCMWORK when a PRODUCTION step is started.

    Or when the production step is completed, and there is a following production step in the same operation. NOTE: This setting is not in use

    Override Operation Sequence in Productions

    If setting is 'ON' -  it is allowed to override the operation sequence at a Production (PWO), e.g. start and finish third operation before second operation. If setting is 'OFF' - the 'set ready for start' button will not show on Production Resource (RES)

    Production Cancel Message if Sales Order is Cancelled

    If setting is 'ON' - a message 'Customer Order Cancelled/Deleted' will be set on the Production Work Order (PWO) if the Sales Order is cancelled.

    Resource Work Log Calculation

    If this setting is 'ON' - Functionality that will calculate work done by Resource and Date (RWL) is activated

    Sub Production Update On Time Change

    If this setting is 'ON' - Sub Production Work Order will be updated when changing production startdate or enddate

    Supplier Account for part change on purchased Products (ART)

    Value in this setting should be a Supplier Account (SUP) that is used when part change is done for products ART) that are bought, - and not build by the firm

    Third country material cost calculation

    If this setting is 'ON' - Functionality that calculates Third country material cost from finished Production, based on Sales Orders (COA) or Shipping Advice (CSA) is activated

    Use New Work Log Table

    This setting will be used temporary by the JHC development team to allow old and new code during the implementation phase of the WorkLog table on Table 3 in WOO. Old code use LCM table 3.

    Use New Work Order Operation (WOO) Archive

    This setting will be used temporary by the JHC development team to allow old and new code during the implementation phase of the WorkOrderOperation Archive WOO. Old code use LCM table 2.

    UseGaugeMeterinShopFloorApplication

    Use GaugeMeter in ShopFloorApplication

    Verification of Product Structure

    If setting is 'ON' - batchjobs that runs verification of Product structures are activated.

    Warning icon for overdue days in resource planner

    Value in this setting is a number of days. Warning icon is set in resource planner at Production Work Order (PWO)/operation, - if the operation is delayed more than CriticalMargin. (CriticalDays > CriticalMargin)

    Allow Update of USEDQTY in PWO KIT

    Allow to add real used quantity in PWO KIT part lines, field USEDQTY. Will overrule planned used quantity.

    Select jobs

    The main tool for operators is the job queue in the Resource (RES) application. Here they will find the jobs released for production.

    To open the Resources (RES) application, find Production in the RamBase menu and then Resource management. Click Resources to enter the RES application.

    From here the operator may enter his own resource by highlighting the item line and pressing ENTER.

    This will open the resource window which lists all work orders registered on himself.

    The folder WorkOrders lists all open work orders which the operator may start. The list of work orders is sorted by planned start date and time, and the status of the work can be seen in the status column. It may be ready to start, in progress, paused or finished.

    Most operators are members of a group with their own work orders. If you are in a resource and would like to view the other members work orders, you can check the box at the bottom called Show jobs for other members of RES/X group. To view work details, press F12 to open the action menu and choose the option Work Details. Here you may inspect the group members, transfer resources and add additional resources to the work order.

    Radio buttons

    You may use the radio buttons to filter the results.

    1. All

      Shows all the operations on the resource.

    2. Active

      Shows all the active operations (ST:3-8) on the resource.

    3. Ready

      Shows all the ready operations (ST:3) on the resource.

    4. In Production

      Shows all the operations in production (ST:5) on the resource.

    5. Wait

      Shows all the operations waiting (ST:2) on the resource.

    6. Completed

      Shows all the completed operations (ST:9) on the resource.

    7. My Tasks

      Shows all the operations registered with the logged in PID as operator.

    To pick a work order to start, highlight the desired work order and press ENTER.

    Resource Work Order Operations (RWOO)

    The Resource Work Order Operations (RWOO) application is used to show the work orders related to a production resource, with all necessary details and links to related documents.

    Work Order Operations filter:

    This is a pre-made filter where you fill in any information you have regarding the work order operations you want to find using the filter fields. You can filter by serial number, work order number, product name, customer's reference number, operator and associated material. For some resources work order lists, it can be useful to filter the list by the material associated with the operation. An example is cutting operations where it may be wise to choose jobs that use the same material, because it leads to less setup time to switch the tool between jobs.The field 'Material name' can be used to filter jobs by material / part.

    How to use the Resource Work Order Operations application
    1. Enter the name of a resource, or click the arrow to search, in the Production resource field.

    2. All work order operations for the resource will be shown in the list below.

    From this list it is easy to check relevant information using the different links in the columns:

    • Work order: The link in this column sends you to the Production Work Order (PWO).

    • Product: The link in this column sends you to the Product (ART) document.

    • Operator: The link in this column sends you to the Personnel (PER) document for the user who is set as the operator for the work order operation. If the work order operation is not started, this field will be empty.

    • Columns with icons:

      • Production Status Info: This link sends you to the application for viewing the work order planning operations.

      • Confirm Picking: This link sends you to the PICK application where you can confirm the picking.

      • Scan Picking: This link sends you to the SCANPICK application where you can scan the picking with a handheld device.

    • Link column (last): This link will send you to the Work Order Operation (WOO) application where the operator can perform actions for the work order operation.

    Logging

    When you have chosen the desired job, and pressed ENTER, you will enter the Machinehours window.

    It is from this window all logging of hours are performed.

    1. To start the job, click the button Start PROD. This will set the production as active, and a new set of buttons will appear at the bottom.

    2. To pause the production, in case of breaktime or similar, click the Pause PROD.

    3. If the production needs to be put on hold for any reason, click the button On Hold. You must state a reason for the delay in the popup. The difference between this and Pause is that On Hold closes the PWO for editing, as putting it on hold usually means a change must be made.

    4. All hours worked logged may be viewed and edited from the Worklog folder in the Production Work Order (PWO) window.

    5. Highlight the desired item line, and press ENTER to edit. The criteria for editing worked hours is that the process has ended.

    The Production Work Order Worklog (PWOWL)

    Use the Worklog (PWOWL) for Production work order (PWO) to log time on operations done for a production work order. You can log time for the operations in the PWO after the PWO is completed. To log time on operations done for Work order operations (WOO) by using the Start and Stop buttons, use the Worklog for WOO application. Refer to The Worklog application (WORKLOG) for Work Order Operatins (WOO). There are two tabs in the workspace,

    1. Enter PWOWL in the program field and select the Enter key to open the application.

      The Work order operations tab

    2. Select in Production Work Order to select the necessary PWO for which you want to log time. The default fiter is In production. Select X to clear the filter if necessary.

    3. The Production work order details pane gives the details of the PWO such as the PWO number, Product in the PWO, and the Product description.

    4. The progress bars pane on the right gives progress bars for Setup time, Run time, Cleanup time and Total time. If there are many Work order operations (WOO) in the PWO, the Total time shows the total time taken by all the operations in the PWO. These times are calculated from the automatically accrued time when selecting the Start and Stop buttons in the WOO and also any logged time from the PWOWL and WOOWL. The Total manhours progress bar displays the sum of the total man hours that are entered manually in WORKLOG for PWO. If the accrued time is within the planned hours, the progress bar is green. If the time exceeds the planned hours, the progress bar is red.

      The Work order operations tab

    5. To add work hours manually for a specific WOO in the PWO, select the WOO in the grid of the Work order operations tab. select in Operator and select the operator name from the list. If you add an operator in the Restricted operator tab of RESCONFIG, The operator name becomes available in the list. If no Restricted operator is specified, you can select any employee in the company from the Operator list. If you do not select an operator in Operator, the time is logged against the employee or operator currently signed in .

    6. In Manhour rate, select the manhour rate from the list. The manhour rates are defined in the Resource configuration (RESCONFIG) application. Manhours can only be added if the Allow man hours setting in RESCONFIG is enabled.

    7. In Step, select the production step. The step can be Processing, Setup or Cleanup. The steps are defined in the Production operations (OPR) application. The default Step is Processing.

    8. In Start at. select to specify the start date and to specify the start time.

    9. In Add time, enter the work hours you want to add to the worklog and select or Ctrl+s. The specified work hours are added to the Total manhours.. To enable the icon, you must specify the Step, Start at and Add time

    10. To clear all the fields except Step, select Ctrl+z.

    11. Select in Operation to inspect the Work order operation (WOO) in the Work order operation application.

    12. Select in Worklog to inspect the Work order operation worklog for the Work order operation (WOO).

    13. Select in Operation to inspect the resource in the Operators list of production work order operations application.

    14. Select in the grid to set a Work order operation to Status ST:9 (Completed). In some cases, you may have to complete picking before completing the WOO. Select Pick and Pick all in the PICK application to complete the picking.

    15. Select in the grid to reopen a Work order operation in Status ST:9. You must select a reason for reopening the WOO. If you specify a new reason that is not in the list, it is added to the list and is available when you next reopen a WOO:

    The Worklogs tab

    Worklogs gives all the worklogs for all the Work order operations (WOO) in the the Production work order (PWO) selected in Production work order. When you create worklogs, you can check if the worklog was created by viewing the Worklogs tab.

    Pick for Production

    When the picking process has been performed, it must be confirmed to ensure strict control of the stock.

    You can use both the SCANPICK and PICK application for this. For details concerning the use of SCANPICK, please refer to the SCANPICK documentation.

    1. Click the button called Confirm Picking to start the confirmation process.

    2. This will take you to the PICK application.

    3. Highlight the item line containing the articles you need to confirm and detailed information will appear on the right side of the screen. Either enter the quantity you want to pick in the number field in the Picked Qty column, or click the Pick All button to pick the full quantity of the stock location. Click the Confirm button when finished.

    4. If everything is completed without errors, PICKING COMPLETED will appear on the top of the screen.

    5. Press ESC to go back to the operation log window.

    6. To complete the operation, click the PROD Completed button.

      • If a Holdpoint have been defined on the operation, this must be approved before the operation is completed using the Approve Holdpoint button.

    Quantity adjustment

    The field UsedQty in KIT makes it possible to add value at part lines in Production Work Orders (PWO) KITs. Use this if the planned quantity does not match the real used quantity.

    Follow this procedure to adjust the quantity:

    1. To open the Production Work Orders (PWO) application, find Production in the RamBase menu and then Production. Click Production work orders to enter the PWO application.

    2. Click the Kit icon to enter the KIT document for the PWO.

    3. Click the Edit Used Quantity icon in the Qty/Time column to open the Edit Used Quantity popup.

    4. Set the real used quantity in the UsedQty field and click the Confirm button.

    Limitations
    1. The setting Allow update of USEDQTYin PWO KIT must be switched on.

    2. PICK has not been initiated.

    3. Material with Class C or M.

    4. KitFixQty can not be used at such part lines.

    Production quantity multiplied

    Some product are used to make a set amount of product. You can add the total quantity on the product using the ProduceInMultipleOf field in the Misc folder. Add a number here and it will be inherited by the Production Work Order (PWO) when it is used in production. The system will force through a number which is a multiple of the given number regardless of the number entered.

    Inspect instructions

    You may see attachments regarding the production item on the operator screen. These may be pictures, drawings or other instructions related to the production, the parts or the kit. These are located to the right in the screen in the Attachments box.

    Make tests and measures

    To the left in the operator screen you can see the LCM Measures box. Here you may view and add measures related to the kit.

    The Measurement (MSR) module is only available if activated for the company.

    Explanations for the measures
    1. DIM: Dimensions.

    2. PIF: Product inspection form.

    3. THR: Thread.

    Add a measure
    1. To add a measure for the kit, for example the dimensions, click the Add Measure icon in the measures column.

    2. This takes you to the Key Characteristics Inspections window. Here you may add relevant information related to the dimensions of the product, tolerance class and the tool used.

    3. When the information has been added, your Personal Identification Number (PID) will be picked up and you will be set as the creator in the UserId column.

    4. Click the CONFIRM button to finish.

    Group Work Order Operations (GWOO)

    The Group Work Order Operations (GWOO) application is used to group multiple Work order operations (WOO) together. This enables you to start, pause, stop or complete all the WOO in the group simultaneously.

    How to group Work Order Operations
    1. Some settings must be enabled in Production resources (RESCONFIG) for WOO to be grouped. You can also enable the distribution of operation time to the grouped WOO. For more information, refer to Resources (RESCONFIG).

    2. Choose the desired resource. The work order operations in Status ST:2 and ST:3, which are not grouped are displayed.

    3. Select Add new group to create a new group. The group is named automatically in the format DD.MM.YYYY - Group N, for example 23.05.2020 - Group. The number after Group is based on a sequence which is reset on a daily basis.

    4. The list to the right is empty, because the group is new. Highlight the desired work orders in the left grid, or use the box in the top right column to choose all available, and select Assign to group.

    5. The list to the right is now populated with work orders, which can be run simultaneously by selecting Run group. The group is available for more additions in ST:1, and is set to ST:4 when the work order operations are started.

    Check serial numbers on partlist

    It is possible to force check that serial numbers have been assigned to parts related to a specific operation.

    1. Enter the Kit Structure you want to have a serial number check on. This is available from Production Work Order (PWO) and Life Cycle Management (LCM) documents. Click the green Kit-icon to access KITDOC.

    2. Highlight the operation in the item lines and press ENTER.

    3. This opens a popup called Structure Operation item. Here you will find a checkbox called CheckSerialNoOnParts.

    4. This checkbox may have been set to default in the actual Operation (OPR) document. If not, the checkbox is presently unchecked.

    5. When this checkbox is selected, serial numbers must be added to the parts in the LCMs part list for the parts that are confirmed as picked, before the operation can be completed. You will receive an error message stating that All serial numbers are not entered.

      • If the checkbox has been selected by error, you can enter the PWO in question, click the Kit icon, select the operation on the item line and press ENTER. This opens a popup where you can uncheck the CheckSerialNoOnParts checkbox.

    6. Enter the related LCM document(s), where you can set the serial numbers in the item lines.

    7. The column serial numbers have a blank text field and a button called Select From SSA in the item lines. You can either enter a unique serial number in the free text field, or click the button and find a serial number from the Goods Reception (SSA) document.

    Replace before production

    You can add a dummy article in productions which you replace with the actual product before production starts. This function is used in situations where it is undecided which product will be used in the final production.

    How to use a dummy product

    1. Find the dummy product, or create a new. The important thing here is to choose YES in the dropdown menu in the ReplaceBeforeProduction field in the Misc folder. Using this article in the production will prompt a warning on the Production Work Order (PWO) in addition to the article structure, with an identifying reference to the article in the structure.

    2. Set up the PWO as normal.

    3. While in the PWO, enter the product structure using the green icon in the upper right corner.

    4. Highlight the item line containing the dummy article (the item with the warning) and press ENTER.

    5. Press F12 and choose the option Replace product in structure.

    6. This will open a popup where you can choose the part you want to replace the dummy article with. Click Confirm when finished.

    7. Back in the work order you will see the warning has disappeared and you can release the order for production.

    Complete the production

    In the Production Work Order (PWO), when all the operations in the structure have been performed, the document will be set to ST:8.

    1. To complete the production, click the Forward to Stock button at the bottom of the screen.

      • If the article has a Preferred Stock Location registered, you can use the Forward to Stock and Move To button. This will add the finished product to the preferred stock location.  

    2. The document will now receive ST:9.

    3. A Goods Reception (SSA) with doctype Production will be created with the produced kit as item.

    Line production method and setup

    Planning method

    The planning method for products where the Production Work Order (PWO) is designed to run at a production line with a continuous flow is different from the method used for ‘station based’ production. Running a production work order at a production line means that the planned start time of operation number 2 should be equal to the end time of the first product (unit) at operation number 1.

    Overlapping operations:

    The total production time for the planned quantity will in this example be one week.  If this product was set up with ‘station based’ planning the calculated total production time would be several weeks.

    What is the impact / advantage of using line production planning

    The line production method solves two issues:

    1. The total production time for a PWO running on a line must be the time from the first product (unit) starts on the line till the last product leaves the line. This will give the correct load and period for the workload and capacity for the involved resources.

    2. The material / parts requirement date is the start date of the operation that the material / parts are linked to.  This has a direct influence on the required date for POs to supplier and the material/parts optimize processes.  And these dates will not be correct when not using overlapping planning for a line production.

    How to specify a product and product structure for line production

    There are some criteria that must be followed to get the functions and planning method to run properly for a line production product:

    1. All operations (OPR) must only have value in the ‘Time’ field (variable production time, production time per unit.  They should never have ‘Pretime’ (setup time) or ‘Posttime’.  That will not work, and the line is not flowing.

    2. Queue time between operations must not be set, the process will not handle this.  This is also a flow ‘blocker’.

    How to enable line production method for a product

    A product is either set for running at a production line or for ordinary ‘station based’ planning.  There is no option to combine these methods for one product by letting some work orders run at the line and some at stations.

    The line production method is enabled / disabled at the product (ART), ‘Misc’ folder, field ‘Lineproduction’ in the ‘DATA’ box.  Value ‘Yes’ (1) = the product is set to be planned by the line production method.

    Permission is given to the duty ‘Prepare product for production’.

    Tools to support line production

    The planning for a line production batch – both for resource planning and purchase planning – will most probably work best when the planning is done for one work order that holds the total quantity to be produced within a production period of 1-2 weeks (or other company preferences).  A large order for a batch that needs several weeks of production time should probably be split into some smaller batches to get appropriate dates for purchase and planning.

    A planned batch is also often preferred to be split into very small batches (some time down to 1 pcs per work order) when the production is to be started.

    There is now available a new multi split tool that simplifies these split processes.  The function is available at production work orders (PWO) that are registered but not released for production, that is:  PWOs with status = 2, 3, 4.

    F12 – Multisplit        Permission given to duty:  Plan production work orders

    Multisplit preparation – building the split table

    There are two methods to build the split table before confirming and starting the action.

    1. Build split table by manually given units and dates:

      The quantity and date is specified as shown in the red dotted box, and the line is added to the table below by the sign.

    2. Build split table by work orders and units:

      Set number of work orders or number of units per order (the other number is calculated), the production start date and days between each start date:

      The builds the split table:

    The suggested lines in the table can be deleted and the operations repeated until the table is as required.

    Multisplit actions

    There are two selectable actions (buttons) at the footer of the application (bottom of the screen):

    1. Split and confirm

      This function will split the PWO according to the specified table and confirm the new PWOs that are created.  The new PWOs will get status = 2 or 3 or 4 when the split jobs are done.

    2. Split and release

      This function will split the PWO according to the specified table and both confirm and release all the PWOs (including the source) for production.  All PWOs will get status = 5.

    How is the split done?

    The user will get a short notice on the screen when one of the actions is selected ‘Batch is started’ and the job is started.  The involved PWOs are blocked for other actions while the batch job is running.

    Please note that sub kits (sub PWOs) are not automatically split by the multisplit function even if the setting ProductionWorkOrderSplitSubOrder is set to ‘ON’.  This is deactivated for line production products.

    Additonal Production Costs (ADC)

    Products of Class = K/KA and their Production Work Orders (PWO) have Operations (OPR) and part/material/sub-products (ART) that defines the operation cost and the material cost for the product. In some cases there are also other costs that the users want to add to the structure. This is, for example, a cost added to cover for the administration cost for purchase or warehousing cost, typically a percentage added on top of the material cost. Or it can be a license cost that applies when running a specific work operation. These added costs are defined in the CST archive via the ADC application. All such added costs are direct costs, that means that they are part of the completed products stock value when included in a PWO.

    The menu to the left lists all the ADCs based on the search criteria. New and active ADCs are displayed by default.

    The area to the right displays the details of the selected ADC.

    1. Name

      The name of the additional production cost.

    2. Cost Target

      Displays if it is fixed or variable cost.

      1. Fixed

        ADC will be added only once for operation in calculations.

      2. Variable

        ADC will be added to each planned/produced article.

    3. Classification

      Additional Production Cost classification.

    4. Value

      The value of the ADC.

    5. Currency

      Displays the default currency.

    6. Value type

      Type of ADC value provided. Amount if value provided is fixed. Percent if provided value is percentage value.

    7. Used in

      This field shows how many Product Structures (KIT) and Operations (OPR) the ADC is used for. The arrow icon to the right also links directly to the KITs and OPRs where this ADC is active.

    How to create a new Additional Production Cost
    1. Write ADC in the program field and press ENTER.

    2. Click the Create new additional production cost button in the lower left-hand corner.

    3. This opens a new popup where you will need to add information:

      1. Name

        Give the ADC a descriptive name.

      2. Cost target

        Set if the ADC has Variable or Fixed cost.

    4. Click the OK button to create an ADC in status 1.

    5. Optional, add information in the Additional production costs data area.

    6. Choose the Activate option in the context menu to activate the ACD.

    The ADC is now in status 4 and can be used in KITs and OPRs.

    Note: If you need to deactivate this ADC, choose the Deactivate option in the context menu.

    Life cycle management

    A Life Cycle Management (LCM) document may, in production, be defined as an informational card containing all key information regarding regarding a product. An LCM document may be connected to a product using an identification process.

    This process may result in

    1. An LCM document connected to a purchased product.

    2. An LCM document connected to several purchased products.

    3. An LCM document connected to a produced product.

    4. An LCM document connected to several serial produced products.

    The LCM document is unique for each unit, or batch of products. Since this document may contain a batch of products, it is not an identifier such as a serial number. A unique LCM document may contain 10 similar products, each with unique serial numbers. It shares similarities with the production number of the chassis of a car in production, while the serial number is the frame number of the car.

    A LCM document will typically contain all historical data regarding the product and its production process. This includes the product origin, serial number, parts, deviation history, service history, rental history, service interval, measurement documents, certificates and other information.

    In an identification process where a product is given a unique production number/LCM document you may choose it from a sequence.

    Tasks relevant for this process

    1. Creating a Life Cycle Management document

      If a product is to be connected to a LCM document it needs to be manually labeled with this number, either if it is a produced or bought product.

    2. Change product

      If the LCM document is connected to the incorrect product it needs to be changed in the system, but all information needs to be retained.

    Settings for Production- Life cycle management

    Setting name

    Description

    Set owner on LCM when CSA is shipped

    Enable this setting to automatically extract the Customer information from the CSA to populate the Owned by fields in a linked LCM when the CSA is shipped

    Auto create Quality Report when performing a part change on LifeCycle

    If setting is 'On' -  Quality Report (QAR) will be automatically created when replacing parts at LifeCycle (LCM). The Quality Report (QAR) will get key information from Life Cycle/ProductionWorkOrder (LCM/PWO)

    Auto Prefix on Serial Number

    It the setting is 'ON', Prefix can be set.  Serial numbers are then automatically generated for Purchase Orders (SPO) where the Product has 'Yes' in AutocreateSnoForSPO or Life Cycle's (LCM) where the Product (ART) has 'Yes' in AutocreateSnoForLCM.

    The setting 'ProductionSerialNumberCounter' must also be set if serial numbers should automatically be generated

    Automatic Serial Number Model

    Value in this setting must be one of the following alternatives. Modelnr.1=Skipper's setup :: Serialnumber will be Life Cycle number (LCM) with or without 'ProductionSerialNumberPrefix' setting first.

    Modelnr.2=DISPLAY's setup. Modelnr.3=Not in use yet. For new customers, use Modelnr.1

    Serial Number Counter

    Value in this setting is a parameter that will automatically generate serial numbers for Purchase Orders (SPO) or Life Cycles (LCM), - if Products (ART) has AutocreateSnoForSPO=Yes. SNOCNT is a counter that will automatically be increased by 1 when a new serial number is generated. The serial number will consist of this parameter and CSV/AutoProductionSerialNumberPrefix concatinated (prefix first). Serialnumber generating will only happen for Productions with LCMDOC=UNIT.

    Functionality can't be used if CSV/ProductionSerialNumberModel is set to SerialModel=1. To edit the Serial counter, type 'SNO' in the program line and use the F12 option 'Edit Serial Number Settings'

    Serial Number Prefix

    Value in this setting is a Prefix of serial numbers. The value will be set before Serial number counter or Serial number from Modelnr.1. Functionality doesn't work when using Serial number from Modelnr.2

    Serial Number Prefix Field from Product (ART)

    Value in this setting is GR1. Information from this field on Product (ART) will be used as prefix. Functionality is not valid for Serial number Model.2. If CSV/ProductionSerialNumberPrefix has a value, this setting will be overridden

    Serial Number Start for Pilot Product Productions

    LifeCycle (LCM) serial sequence number for pilot series production (Product status=3). If value in the setting is '10', - LifeCycle (LCM) serial number after ""<part>-"" will start on '10' or last used above 10+1.

    This functionallity will only work if the setting ProductionSerialNumberModel has value=2

    Serial Number Start for Prototype Product Productions

    Value in this setting is a number. If value is '1', - LifeCycle (LCM) serial sequence number for prototype production (Product status=2 will get LifeCycle (LCM) serial number after "<part>-" start on '1'. This setting will only work if the setting ProductionSerialNumberModel has value=2

    Serial Number Start for serial Productions

    Value in this setting a number that is used when calculating Serial sequence number for serial production (Product in Status=4). If the value is '100' - LifeCycle serial number (after ""<part>-"") will start on '100' or last used above 100 + 1.

    This setting will only work if the setting ProductionSerialNumberModel has value '2'

    Life Cycle Management (LCM)

    Life Cycle Management, (LCM), is a document which holds key details about each unit or batch to be produced. The document is created at production release, when the Production Work Orders (PWO) is set to ST:5. Details are recorded until the production ends. Depending on the value of ART.LCMDOC, LCM documents are created per unit or per batch. The following rules apply:

    1. UNIT: One LCM document per unit.

    2. BATCH: One LCM document per production series (PWO). Material supply from different sources may cause the original batch LCM to be split.

    To open the Life Cycle Management (LCM) application, find Production in the RamBase menu and then Life cycle management. Click Life cycles to enter the LCM application.

    Folder descriptions
    1. Part List

      The Part list folder lists any materials associated with a production for which there is a tracing requirement.

    2. Operations

      The Operations folder lists details about each operation, such as the operation sequence and time consumption.

    3. RMA Requests

      The Return Material Authorization (RMA) folder is used to hold information about the return and repair or replacement or refund of defective goods.

    4. Used in

      For sub assemblies. Showing which production that the LCM is used within.

    5. Service

      Shows the service history.

    6. Rental

      Shows the rental history.

    Set owner for LCM

    You can specify the owner of the LCM. The owner can be supplier or the customer. There are 2 ways to set the owner for an LCM.

    1. If the CSV setting SetOwnerOnProductUnitWhenShipped is enabled, then the owner fields are updated with the customer information in the CSA, but only if the owner fields were previously empty. If the owner fields are not empty, these values are not overwritten. The CSA must already be linked to the LCM. Refer to Settings for Production- Life cycle management.

    2. You can also specify the owner manually. To do so:

    1. Select to the right of the Owned by label in LCM.

    2. In the Product Owner window that appears, select Customer or Supplier as the owner. If you selected Customer, the CUS icon is displayed. If you selected Supplier, the SUP icon is displayed.

    3. Select the CUS icon to display the Select Customer (CUSSELECT) window where you can select the customer by double clicking the necessary Customer name.

    4. Or select the SUP icon to display the Select Supplier (SUPSELECT), where you can select the necessary supplier by double clicking the Supplier name.

    5. Select at the right side of the Owned by label to remove the owner information from the LCM.

    Create LCM

    There are three situations where a Life Cycle Management (LCM) document is created:

    1. Automatically created from a Production Work Order (PWO) by Release for Production Service

    2. Manually created without a preceding production (for rental and service)

    3. Imported into the system from OEM production

    Create a new LCM document

    LCM documents are usually generated automatically, but may be created manually if needed. This may be the issue if a company buys kits it did not produce themselves and want to have a LCM document related for service reasons.

    1. The requirement for creating an LCM is that the Goods Reception (SSA) with the purchased kit is in ST:3 or ST:9.

    2. Open the SSA and register it to ST:3 and enter the item.

    3. Choose the Create product units (LCMs) and sub product units option in the context menu.

    4. To create LCMs for purchased products, choose the Create product units (LCMs) and sub product units option in the context menu.

    5. In the SSA item view, select View product unit (LCM) in the context menu to inspect the LCM documents.

    Change parts and inspect LCM

    Life Cycle Management (LCM) documents are used to track all changes in a product during its life cycle. There are situations where a kit needs to have one or several parts replaced, which needs to be registered in a LCM document for traceability and service reasons.

    The qualifying criteria are:

    1. The LCM must be in production,

      or

    2. There must be a service order for the LCM.

    Changing a part in a kit
    1. Open the related LCM document to the kit where you want to change a part.

    2. Here you will see the Change icon to the right in the item line. The icon is two overlapping sheets of paper.

    3. If the desired part you wish to change is not present in the document, click the Add Part from Structure if it is present in the structure, or Add Part from ART if you need to find it in the Product (ART) application.

    4. Highlight the desired part and press ENTER.

    5. Click the Change part icon to open the Change LCM Part popup.

    6. The part will now be selected and you must now choose what to do with the replaced part. The options are:

      1. Returned to Stock

        The old part will be put back into stock. A return sheet is printed, part must be put back in stock. The cost is not added to production.

      2. Returned to Supplier

        This option returns the faulty part back to the supplier. This creates a Supplier Return (SRT) document with a reference to this change. The cost of the part will not be added to the production as the supplier will carry this cost.

      3. Scrapped

        This option creates a Stock Correction (SAW) document and the part is scrapped and a new part is substituted in the production.

    7. Press ENTER on line to select Lot. This will add the part to the To be replaced with field.

    8. Choose what to do with the replaced part in the Replaced part to be field. Below you are presented with four fields which requires information concerning the change, the reason for it and what to do with the replaced part.

      1. The Create QAR-field ask you if a Quality Assurance Report (QAR) document is to be created with a reference to the change. You may choose YES or NO, based on your use of QAR documents.

      2. The Caused By field gives you the option to point to where the fault lies, which is either with the supplier or the production.

      3. The Reason for Change field is a freetext field where an explanation must be entered.

    9. Choose if a QAR document is to be created in the Create QAR drop down menu.

    10. Enter a Caused by option.

    11. Add info on the reason for change.

    12. Enter the destination stock location for the replaced part in the Stock Location field. This field will be pre-filled with a default destination if you have a Stock Location (STL) defined as default stock location when part is changed in LCM in the Stock Location Details area in the STL application.

    13. Click the Confirm button to confirm part change. This takes you back to the LCM document and you will see the Part Change: Picking in progress icon. Information regarding the change can be seen in the Replacement column.

    14. Click the Part Change: Picking in progress icon, which will take you to the Pick Goods application.

    15. Proceed with the picking process by entering the desired quantity and click the Confirm button at the bottom. If you use the Pick All button you will not need to click Confirm.

      Note: If you have made an error, you can click the Part Change: Picking Completed icon on the LCM to return to the Pick Goods application. Clear the filter if needed and press ENTER to view all picked items. Click the Undo Pick All button to restart the pick process.

    16. When you create the LCM, RamBase builds the part list as follows.

      1. Create items for 1 pcs as shown above for parts with unit = pcs and with both INCLUDEINLCMPARTLIST = Yes (1) and

        REQUIRESERIALNOTOSHIP = Yes (1) . The last of these two fields is shown in ART as ‘RequireSnoToShip’. Exception from this rule:  Always create items for 1 pcs for sub assemblies with unit = pcs.

      2. Create items with total quantity for parts with unit = ‘pcs’ and only INCLUDEINLCMPARTLIST = Yes (1). The result of this for the example above is given in the figure below.

    17. By opening the line to, for example, replace 2 of these 5 parts by first modifying the existing line to 3 pcs and then adding a new line for pcs of this part by the function Add part from Structure and modify the quantity to be added to 2 pcs.

    18. In Add part from structure, select the quantity to be added (the quantity that was reduced at the existing line).

    19. Select the part and change the quantity in Override KitQty. It is important to first reduce at existing line and then add correct quantity at the new line in order to not exceed the total quantity for the part.

    Service on LCM

    The Service folder in the Life Cycle Management (LCM) document displays the service history of the product, and the related service jobs (ART with Class = KM) with service interval information.

    The service kits and service operations are entered in the Product (ART class KM) application, and can also be added to the LCMs as standard service jobs/types for the product. Defining a service part/operation as main service must be done on the specific article (the LCMs product) using the Main Service checkbox in the service folder on the ART. Running a main service will automatically set the next service at the LCM based on the service interval defined by the service interval for the job.

    The next service column states when the next planned service will be. This date is calculated when a service job/operation is completed based on its service interval. The service interval is defined in the Service Type (SVT) application and chosen on the specific article or operation in the SVTREF field.

    Dismantle product

    1. The purpose of the function

      To be used if a product that consists of parts and sub products should be dismantled to single parts or sub products.  The original product will then be taken out of stock and the products LCM will be marked as dismantled.

    2. Conditions for using the function

    • The product must have a serial number and a LCM document.  The product can be built in house or a purchased product.

    • The LCM must be available (free) at stock, it can not be linked to any customer order, production order or shipping advice.

    • The LCM can not be linked to an active service job.

    1. Permission

    2. Description of the function

    Duty: Perform dismantle product process.

    The function is available at the LCM document – F12 ‘Dismantle Product’.  This opens a window to start the process.  One input is required before using the ‘Create’ button:

        - The stock location where the product is taken from must be selected, picking is then done by the function when the PDI process is confirmed and closed.

    Create

    - Creates the PDI (Product Dismantle).

    - Sets the dismantle document id at the LCM and shows ‘DismantleDoc   PDI/nnnnnn’ at the LCM.

    - Creates a SAW (stock adjustment warehouse) document to take the product from stock. This has ST=0 and is registered to ST=9 when the dismantle process is completed.

    The SAW has DOCTYPE = DISMANTLE and StockAdjustCode = 18 and YourItm = PDI/nnnnnn.

    - The serial number at the SSA document is occupied by the SAW.

    PDI document

    The PDI document presents the product, the LCM, the serial number, the product value from the SSA and a table of parts that is copied from the LCMs part list.

    How to select which parts / sub products to come out of the dismantle process

    - Enter the quantity in the Dismantled Qty column for the parts/products to be put to stock.

    The Price is the original price from the parts SSA, but that can be modified by the user.

    - If the part is not present in the table:  Add Part and set requested Qty and Price.

    The Amount column will show value for the parts/product that are selected and will be in local currency.  The total sum for parts/modules going to stock is shown in the header as Sum disconnected value.

    The dismantle document has status = 1 until either discarded or confirmed as completed.  The PDI document can be opened from the LCM.

    Sub modules has the sub LCM reference in the column ‘Product unit’.  The icon can be used to expand the sub module abd the part list from that will be added as extra lines to the PDI.

    Discard process

    The button ‘Discard process’ will undo the PDI preparation.  The SAW is canceled, the SSA and serial number (LCM) is freed and the PDI document is discarded.

    Confirm process

    The button ‘Confirm process’ will complete the dismantle process:

    - The SAW is registered to ST=9 and the original product is taken out of stock and only exists as history.  A PAT (product Account Transaction) document is created for the SAW, the product value is deducted from the stock value.

    - The product LCM gets EndofLifeAt = date and time of confirm PDI process and EndofLifeReason =  DISMANTLE.

    - New SSAs are created for the parts and products that are coming out of the product and these are shown in the Destination goods reception column at the PDI.

    Cost and time

    Cost and time is the base for calculating the production cost of a production order. Cost and time should be planned for each product to be produced. Cost of goods, resource use and time for work time and operation time. This process may be called the estimation process.

    This process may result in

    1. Cost and time estimated for a new product.

    2. Cost and time estimated for a modified product.

    3. Cost and time estimated for a special production.

    If new products up for production is created and scheduled, new estimations regarding time and cost will need to be implemented. There might be requirements regarding time and cost re-estimation in connection with modifying an existing product or any customization, which can be re-estimated case by case. If estimated cost differs from the real cost, there is a cost deviation. These will, for example, occur in instances where the resource use related to an operation is higher or lower than estimated.

    Accrued expenses will be calculated continuously throughout the processes in the production and it is possible to assess these in relation to the estimated cost. This enables you to reveal and trace any cost deviations.

    Tasks relevant for this process

    1. Calculate estimated cost

      Costs may be estimated based on experiences, drawings, user manuals, numbers from the purchase department and other indications.

    2. Inspect real cost for active productions

      By following up the status through reports and other tools, it is possible to follow the actual costs at any step in the production process.

    3. Following up estimated cost related to real cost

      By following up the status through reports and other tools, it is possible to find and fix any deviations and implement corrective measures.

    Settings for Production- Cost and time

    Setting name

    Description

    Cost deviation control in Production

    Value in this setting is either Amount or PCT (percent). On complete operation - If total logged operation costs differs from Planned operation costs, - an alert will be set on the operation according to the percent or amount in the setting  ProductionCostDeviationValue

    Value for cost deviation control in Production

    Value in this setting is an Amount or a Percent. When operation is  completed - If total logged operation cost differs from Planned operation cost, - an alert will be set on the operation according to the value in this setting

    Work Log Deviation Lower Limit Percentage

    Value in this setting is a percentage. On complete operation - If total logged operation time differs from Planned operation time, an alert will be set on the operation according to the percentage in this setting

    Work Log Deviation Upper Limit Percentage

    Value in this setting is a percentage. On complete operation - If total logged operation time differs from Planned operation time, an alert will be set on the operation according to the percentage set in this setting

    Cost Deviation

    When running a production you might face a cost deviation due to incorrect time usage assumptions in the planning phase. This will be the case if an operation, which is defined to take a certain amount of time, spend less or more than the estimate. Every operation has a price related to the time usage, and this is calculated by how long the operation actually takes.

    Cost deviations are flagged in the Production Work Order (PWO) by a yellow warning icon at the top left called Cost deviation.

    There are two methods of handling a cost deviation, either by accepting the deviation or by updating the structure in the article archive to better estimate time usage in future productions.

    Click the Cost deviation icon to view the deviation in question.

    Click the warning icon on the operation containing the deviation to perform an action.

    Here you may either update the structure or accept the deviation using the buttons at the bottom. Use the history seen in the item lines to get a better estimate for future productions.

    Inspect calculated cost

    Cost of productions are calculated throughout the production process. Production costs can be inspected from a Production Work Order (PWO) under the Cost folder.

    Estimated cost

    Estimated cost is the estimated cost which is based on the kit and the related costs. There are both fixed and variable costs. Variable costs are often operations, as they may vary based on time usage.

    Planned cost

    The planned cost is one step further, when the articles to be used in the production have been linked to the PWO. The prices may differ from estimated cost as the articles used may in reality cost more than the initial estimate.

    Accrued cost

    Accrued cost is the actual costs when the production has started which is calculated by picked parts/materials and logged operation time.

    Add repair info on Life Cycle Management for Service Report

    It is possible to generate a service report from a Customer Deviation (CDV) document using the F12 option Service Report. The criteria is that the CDV have been created with the Customer Deviation Code (CDC) Return Goods for Repair, or Repair and Return to Stock. The report can also be re-generated from the CDV using the F12 option Print Copy/Resend.

    Adding the information for the report
    1. Enter the CDV in question. After opening the document, you will be able to see the field LcmDocid and the link to the specific Life Cycle Management (LCM) next to it. Click the link to open the LCM.

      • An alternative is to find the LCM using the Supplier Shipping Advice (SSA) from when the goods were received from customer.

    2. In the LCM document you will see a set of folders. Click the folder called RMA Requests. This folder keeps a record of all the repairs performed on the product.

    3. The item lines in this folder shows the different related CDV cases. Next to these is an icon. Click this to open a popup called Service Info. Enter the details regarding this situation and click Confirm when ready.

    This information will now be available for the Service Report.

    Inspect cost during production

    Cost may be inspected during production from the Cost folder in the Production Work Order (PWO).

    The running cost may be inspected in the Accrued cost column.

    When the production is complete, you will see the complete cost in the Price field located in the Part box.

    Sales calculator

    The sales calculator tool is designed to allow the user to start building the product structure during the sales process and to calculate and specify cost estimates and sales estimates.  This process can start at the sales request from the customer and will flow through the complete process from the request to the delivered product.

    The Sales Calculator functionality
    1. Copy an existing structure version from the product to the sales document item or create a structure from scratch.

    2. Add/replace/delete material, parts, operations, sub structures.

    3. Modify quantity and work time for each item in the structure.

    4. Set/modify cost price for each element in the structure or sub structure.

    5. Set sales price or gross margin at each element in the structure.

    6. Select materials/parts where the supplier quote request is needed. A supplier quote can be selected as cost price for the actual element in the structure.

    Any change to the sales items main structure (KIT) or one of its sub structures will result in a recalculation of the total cost and total sales price upwards through the structure and the calculated sales price may be selected as the valid price for the sales request/quote/order.

    Start the process

    The product must exist in the product master (ART) and is selected to the sales request/quote/order.

    An example article can be a Sales Quote Request (CRQ) item where the product and quantity is selected. There are two F12 options that can enable the sales calculator tool:

    1. Copy Version from ART

      User can select which version of the Product (ART) structure to copy from to the sales item.

    2. Create Special Structure

      Creates an empty structure to build from scratch, all operations and materials/parts must be added.

    The result of these functions is that a structure (KIT) is assigned to the sales item and a yellow structure icon is available to work with the structure.

    The tools are also available from the sales document item line(s):

    The green icon called Inspect Special Structure starts the KIT designer tool.

    The white and blue icon called Inspect Sales Calculator starts the sales calculator tool.

    The KIT designer tool

    The designer tool is the same tool that is used for building product structures (at ART) and modifying Production Work Order (PWO) structures. There are three main differences when working with the tool at sales document items:

    1. There is no versioning functionality, one is working at one edit-version belonging to the item. However, forwarding the sales document item to a new document, for example a CRQ to a new CRQ, copies the structure and creates a new structure for the destination document. Version control can be achieved by using that method.

    2. There is drill down functionality to work with the sub structures.

    3. Adding a part with Class = K/KA to one level will result in an automatic copy of that parts structure and sub structures to KITs that will be added to the actual structure. Changes to the contents of any level in the structure (adding parts/operations, changing hours/quantity, deleting operations/parts) will lead to a full recalculation of costs bottom up.

    The calculator tool is also available when working with any of the structure levels via the View Calculator icon in the upper right corner of the designer tool (KITDOC) screen.

    The KITDOC application will for these structures (KITs) belonging to a sales document item also show the calculated unit cost and total cost.

    The KIT sales calculator tool

    This tool is used to view/set/change the cost price and sales price per material/part/sub assembly/additional cost line within the main structure (KIT) or within a sub structure (KIT). There is no limitation of sub levels.

    Each level shows information about cost per unit to be produced and the total cost of units needed to fulfill the requested quantity at the top level.

    This example is for the top level, a product that has one assembly operation and two sub structures that have their own structure below this. The sales calculator tool for one of these is opened via the icon behind the Class icon at the line. Please note that the under laying structure is not available via the yellow class icon when in calculator view.

    Details shown in the tool
    Product

    The product, the product description (Text) and the requested quantity at the sales document item shows at all levels. At the top level in upper left part as in picture above and at lower levels as in the picture below:

    The product and requested quantity is shown at the top.  The sub assembly product and quantity required for the top product quantity is shown below.

    This is the total cost for one piece of the product/sub product that the structure level (KIT) represents. The details are:

    1. Operation Fixed Cost

      Sum of Fixed operation cost for all operations within this or under laying structures (KITs) per piece of this level.

    2. Operation Variable Cost

      Sum of Variable operation cost for all operations within this or under laying structures (KITs) per piece of this level.

    3. Material Cost

      Sum of Material cost for all materials/parts within this or under laying structures (KITs) per piece of this level.

    4. Added Fixed Cost

      Sum of Fixed additional cost for all added cost elements within this or under laying structures (KITs) per piece of this level.

    5. Added Variable Cost

      Sum of Variable additional cost for all added cost elements within this or under laying structures (KITs) per piece of this level.

    The sum of these are shown as Total Cost (per piece).

    NB !  The values are always shown in local currency, the home currency for the production company.

    1. Total Cost/<cur>Cost details per piece multiplied with quantity of the product/sub product to be produced. In home currency.

    2. Sales Price Per Piece

      The CalculatedPrice is shown in the sales document item currency and is the calculated sales price based on the sales prices for the elements in the total structure. Current SalesPrice is the actual sales price at the sales document item. This is only shown at the top level. Clicking on the floppy-disk icon will store the calculated price to the sales document item. This is only available at the top level.

    The details table

    The table shows all elements (lines) for the current structure level. All operations, material/parts and added costs if this is used.

    The columns are:

    1. St

      This is the status (St) of the operation (OPR) or material/part (ART) for the actual line.

    2. Pos

      When building a structure (KIT) there is a field Pos (KitPos) available to specify the parts position reference at e.g. the drawing, the customers BOM, the circuit board, etc.

    3. Class

      The operation or material/part Class.

    4. OpNo

      The operation number in the structure for the operation/material/cost.

    5. Qty/Time

      Operation time/quantity per piece for the product/sub product.For operations: Time per piece. PreTime and PostTime is not included.For material/part: Needed quantity for one piece of the structure’s product.

    6. Part/Operation

      Material/Part/Operation part number/operation name and description.

    7. Hw

      Not applicable. Will be removed later.

    8. Pre/Post/Queue

      PreTime, PostTime and queue time set for the operation.

    9. ResTO/<cur>

      A part of the operations sales price can be assigned as earned value for the resource that is used for the operation. Value is added to daily sales price value for the resource work log. Value is always in home currency.

      NB !  Shall only be used if the company has a defined setup for this functionality.

    10. Margin

      Calculated margin for the line, based on the lines sales price and cost price.

    11. SalesPrice/<cur>

      The sales price for one line is in home currency and is the total sales price for the hours/quantity that is specified in the Qty/Time column.The price is automatically set by the following priority:

      1. Agreed sales price for the customer.

      2. Price set at the line in the product (ART) structure.

      3. Standard sales price.

      4. Calculated based on the company minimum gross margin setup.

    12. Quote

      A select quote icon will show if there exists one or more valid supplier quote for the material/part. If a quote is selected the quote reference, e.g. SQU/nnnnnn-n will show in the column, and the purchase will then be based on the selected quote.

    13. Variable Cost

      The variable cost for one line is in home currency and is the total variable cost for the hours/quantity that is specified in the Qty/Time column.

    14. Fixed Cost

      The fixed cost for one line is in home currency.

    15. Cost/<cur>

      Sum of the values in columns Variable Cost and Fixed Cost. Always in home currency.

    Changeable values in the table

    The following columns in the table may be changed by the user:

    1. Margin

      Changing the margin will recalculate the SalesPrice based on the Cost and the given margin. The margin is not stored at the structure line, it is only a calculated value.

    2. SalesPrice/<cur>

      The sales price can be changed by the user at each line and the new value is stored for the line. The total calculated sales price is also recalculated.

    3. Variable Cost

      The variable cost can be changed for operations and material/part lines, but not for sub structure lines. The cost of a sub structure can only be changed via the table of the sub structure.

    4. Fixed Cost

      The fixed cost can be changed for operations belonging to the actual structure level.

    Logging administrative hours before starting production

    Logging administrative hours on a Production Work Order (PWO) document before initiating the first operation is not possible in principle, but it is possible to add an operation where you may log administrative hours before initiating the first production operation.

    The first step will be to create a new operation where the administrative hours can be logged. This operation may be called Hour Logging for example. This operation will be added to the kit later in the process. Remember that any cost set on this operation will be added to the stock value of the kit. Please see the documentation concerning creating operations. Also remember that the resource which will contain the administrative hours needs a price of 0, so the total cost will remain unaffected.

    1. Create a Production Work Order (PWO) based on need or for stock increase.

    2. Enter the PWO document by typing PWO in the program field and press ENTER. Highlight the desired document and press ENTER.

    3. Click the green (or yellow for special structures) kit icon to the right in the window to enter the kit structure.

    4. Click the Copy Version 1 icon in the upper right corner to make a new version of the current version.

    5. You will now have a new version in ST:1, which is possible to edit. There will also be a new tab called Kit Designer. Click this tab and click the icon Switch view to operations in the upper right corner.

    6. On the right you can see the parts and operations for the kit. You may now add the operation to log hours to log time. Drag the operation to the kit and drop it as the first operation in the structure. As long as this operation is active, the remaining operations will not be started.

    7. Go back to the Kit Details tab and press the Activate Version icon at the top. This will set the document to ST:4.

    8. Go back to the original PWO document and click the Release for Production icon at the bottom. This will set the document to ST:5 and a LCM document have been created.

    9. Enter the LCM Documents tab in the PWO document and highlight the main LCM document (the first item line) and press ENTER.

    10. You will now be in the Resource view where you must highlight the item line and press ENTER.

    11. This will open the Machine hours view. Click the Start PROD button to start the operation and start logging hours.

    12. Press the PROD Completed button when the planning, procurement or other pre-production work is done to proceed with the rest of the production as normal.

    Cost & Time deviation control for production work orders (PWO)

    A production company needs some tools to be able to monitor the cost status for a production (project) and also deviations in logged vs planned operation time.  Deviations can be caused by simple logging errors by the operator, not realistic planning or problems that occurs and delay processes.  It is also important to be able to get alerts for operations where the accrued cost has passed the planned cost + a ‘warning limit’ to follow up possible problems.

    Cost deviation control

    There are two company settings that control the cost deviation limit and alert:

    - ProductionCostDeviationLimitMethod : Selectable values: AMOUNT, PCT

    One can choose if the cost deviation per operation is to be checked vs a value limit or a percentage limit. Deviation control will run per operation in the production work order (PWO) Kit.

    - ProductionCostDeviationValue : The limit before approval is needed, Amount (in local currency) or Percentage. Format: Decimal.

    Calculation method and alert

    Calculation:

    Each operation within the PWO Kit has a field CostDeviationAmount that is calculated to the operations Planned cost (fixed + variable) * -1 when the operation is started.

    The accrued operation cost is increased for each pause of the operation (and by complete operation), and that also reduces the negative CostDeviationAmount.

    The CostDeviationAmount is also recalculated if the PWO-Kit is changed (new version).

    Formula for calculation: CostDeviationAmount = Accrued cost (Fixed + Variable) - Planned cost (Fixed + Variable).

    Each operation within the PWO Kit also has a field CostApprovedValue that is calculated to be:

    Planned cost (fixed + variable) + ProductionCostDeviationValue (calculated to amount if PCT is the selected method).

    This CostApprovedValue is calculated (set) at the operation when CostDeviationAmount becomes a positive value, which means that accrued cost has become higher than the planned cost.

    Formula for first time setting of CostApprovedValue:   Planned cost + ProductionCostDeviationValue .

    Alert:

    Each operation within the PWO Kit has a field CostDeviationAlert .  This is a ‘boolean’ field, ‘0’ = false (no alert), ‘1’ = true (alert).

    CostDeviationAlert is set to ‘1’ (alert) if CostDeviationAmount > CostApprovedValue - Planned cost.

    The program will check if operation should be alerted by each pause/stop of operation and by making new version of the PWO Kit.

    NB!  Alert is not given if the ProductionCostDeviation*-settings are not used.

    CostDeviation Alert handling:

    Operations that has CostDeviationAlert = ‘1’ should be checked by cost controller / manager / planner.

    Such alerts can be found by / is visible / can be handled in the following applications/views:

    1. PRODUCTION , the new production overview application:The ‘Deviations’ box will show if such alerts are set.

      Click on the number for ‘Cost deviation’ will open the report ‘Production Cost Deviation Alert’ that gives cost values.  ‘Enter’ on a line in the report opens the actual PWO where the alert can be handled.

    2. At the production work order (PWO), behind the field ‘CriticalDate’:

      The yellow alert icon and the text ‘Cost deviation’ will show if one of the PWOs operations has the alert set.

      Click on this opens the PWOCRITICALDATE window:

    3. PWOCRITICALDATE (list of the PWOs operations):The column ‘CostDeviation’ shows the CostDeviationAmount and the yellow alert icon at the operation that has the alert set.

      Click on the amount to handle the alert, the popup ‘Cost Deviation Approval’ is opened.

    4. OPRCOSTDEVIATION – popup for cost deviation approval:

      Explanation using the above picture as example:

      - the Planned cost for this operation was 800 (NOK).

      - the ‘default’ CostApprovedValue was calculated to 880 (NOK) because of the ‘settings’ (PCT, 10).

      - this operation has had an alert earlier because accrued cost passed the ‘default’ approved value, and the last approved value (Last CostApprovedValue) was set to 1000 by UserId 6610. The alert was then cleared. Each approval will create a record in the revision log at the actual Kit.

      - the work is continued, accrued cost is now increased to 3200 (NOK) and new alert is set.

      New CostApprovedValue should be set to a value that the operator and manager agree upon and button ‘Approve’ will set this and clear the alert again.

      The ‘Approve’ button is limited to the permission ApproveProductionOperationCostDeviation and the duty Control and approve production cost.

    5. The ‘shopfloor’ application ‘MACHINEHOURS’:

      Cost deviation shows in the mid of the screen and the popup for viewing details / approve is opened by clicking on the amount.

    Work log Deviation Control

    The purpose of the work log deviation alert is to easily find and control completed operations (operation status = 9) where the difference between the planned work time and the total logged work time is below or above the decided thresholds.  This makes it easier to find operations where the operator has forgotten to start / stop in time and where the actual work time differs much from the planned time.

    Calculation:

    The field WorkLogDeviationPct at each operation is calculated when the operation is completed (KITOPST =>9).

    Formula:  (logged time – planned time) * 100 / planned time.

    So the WorkLogDeviationPct is the deviation time in percentage when comparing logged and planned time.

    Examples:

    - Planned 10 hours, worked 8.5 hours:    WorkLogDeviationPct =  - 15

    - Planned 10 hours, worked 11.5 hours:  WorkLogDeviationPct =    15

    There are two company settings that control the work log deviation limit and alert:

    - ProductionWorkLogDeviationLowerLimitPct: Should have a low negative value, e.g. - 15.

    If the calculated WorkLogDeviationPct  < this limit: work log alert will be set by complete operation, logged operation time is too low compared to planned time and below the limit for setting the alert.

    - ProductionWorkLogDeviationUpperLimitPct: Should have a low positive value , e.g. 15.

    If the calculated WorkLogDeviationPct  > this limit: work log alert will be set by complete operation, logged operation time is too high compared to planned time and above the limit for setting the alert.

    Alert:

    Each operation within the PWO Kit has a field WorkLogDeviationAlert .  This is a ‘boolean’ field, ‘0’ = false (no alert), ‘1’ = true (alert).

    WorkLogDeviationAlert is set to ‘1’ according to the rules and settings described above under ‘Calculation:’.

    The program will check if the operation should be alerted by making new version of the PWO Kit and if logged operation time is adjusted manually by the available tool for this.

    NB!  Alert is not given if the ProductionWorkLogDeviation*-settings are not used.

    WorkLogDeviation Alert handling:

    Operations that has WorklogDeviationAlert = ‘1’ should be checked by cost controller / manager / planner.

    Such alerts can be found by / is visible / can be handled in the following applications/views:

    1. PRODUCTION , the new production overview application:The ‘Deviations’ box will show if such alerts are set.

      Click on the number for ‘Work log deviation’ will open the report ‘Production Time Deviation Alert’ that gives some cost values and time values.  ‘Enter’ on a line in the report opens the actual PWO where the alert can be handled.

    2. At the production work order (PWO), behind the field ‘CriticalDate’:

      The yellow alert icon and the text ‘WorkLog deviation’ will show if one of the PWOs operations has the alert set.Click on this opens the PWOCRITICALDATE window:

    3. PWOCRITICALDATE (list of the PWOs operations):The column ‘TimeDeviation’ shows the WorkLogDeviationPct and the yellow alert icon at the operation that has the alert set.

      Click on the value to handle the alert, the popup ‘Worklog Deviation Details’ is opened.

    4. OPRWORKLOGDEVIATION – popup for worklog deviation details and approval:

      Explanation using the above picture as example:

      - the Planned time for this operation was 5 hours.

      - the operation was completed and total logged time is 0.01 hours. WorkLogDeviationPct was calculated to -99.80 and that is lower than the ProductionWorkLogDeviationLowerLimitPct (-15).

      - this operation has therefore WorklogDeviationAlert = ‘1’.

    5. There are two options to handle this alert:

      1. The deviation is ok, no need to adjust the logged operation time:

        Press the ‘Approve’ button. The alert is switched off and will be logged in the KIT revision history.The ‘Approve’ button is limited to the permission ApproveProductionOperationTimeDeviation and the duty Control and approve production cost.

      2. The logged time should be changed (forgot to start or stop in due time):- ‘Escape’ from the popup, back to:

        - ‘Enter’ on the line with alert opens the worklog list for the operation:

        - Enter on the line that should be adjusted:

        Use ‘Edit Worktime’ to adjust the logged time.  This will recalculate total logged time, the WorkLogDeviationPct and the WorklogDeviationAlert.

    6. The ‘shopfloor’ application ‘MACHINEHOURS’:

      Worklog deviation shows in the mid of the screen and the popup for viewing details / approve is opened by clicking on the amount.

    Deviation handling

    Deviation handling may be defined as the process where actions are performed based on deviations. This process have clearly defined rules for which actions are involved in the different deviation scenarios.

    This process may result in

    1. Scrapping of one or several products.

    2. Part change on one or several products.

    3. Modification of one or several products.

    If deviations related to the production occur, which makes it impossible for the company to approve the result of the production, it must be handled by a set of specific actions. The production manager clarifies the situation with the second party to find a solution. The solution defines the deviation handling.

    There are normally three methods of dealing with production deviation. The first is that the product is scrapped and written off as wastage, or dismantled and the parts are put back into stock.

    If a raw material is incompatible, or suffers from faults, which has not affected the finished product, it may be changed. This method allows you to handle the defect material simultaneously as you finish the production after a successful part change.

    If production deviations are discovered after the production is finished, and you would like to reproduce the finished product in a new production, it is called modification. This method is more time and resource consuming than scrapping, but it may be beneficial in certain situations.

    Tasks related to this process

    1. Create a deviation document

      Deviation documents to customers or internal can be made to handle a deviation.

    2. Handling deviation based on actual factors

      Deviation handling can be performed based on actual terms to satisfy both parties.

    3. Completing deviation

      After the deviation has been handled, it needs to be cleared with customer or internally.

    Settings for Production- Deviation handling

    Setting name

    Description

    Default value NO for Warranty Conclusion in Deviation (CDV)

    Defines default value for WarrantyConclusion field, when Warranty is 'No' in Deviation document (CDV)

    Default value YES for Warranty Conclusion in Deviation (CDV)

    Defines default value for WarrantyConclusion field, when Warranty is 'Yes' in Deviation document (CDV)

    Use Warranty in Customer (CUS) Deviation (CDV)

    If this setting is 'ON' - Company is using Warranty in Deviation (CDV), and WarrantyDate is transported to Sales Order (COA). If setting is 'OFF' - The field WarrantyDate is not showing in the Deviation screen

    Replace parts in completed sub assemblies during production

    In cases where you are working with articles which include sub assemblies, you might need to replace parts in completed sub assemblies during production. This is normally done to products when still in production or at service, but is also available at sub assembly included in an open PWO.

    1. The first step will be to identify the part in the sub assembly that needs to be replaced or scrapped in the related Life Cycle Management (LCM) document to the Production Work Order (PWO).

    2. One alternative is to replace the complete sub assembly, but if possible the following method must be used to change a part in the faulty sub assembly. Press the LCM link under the column Lot/HeatNo.

    3. To the far right you will be able to see the Change Part icon which is two papers aligned. Press this to open the Change LCM Part popup. The Change LCM Part popup displays the warehouse stock of the replaceable parts. You may look through this list to see your options.

    4. If the desired part you wish to change is not present in the document, click the Add Part from Structure if it is present in the structure, or Add Part from ART if you need to find it in the Article (ART) archive.

    5. Highlight the desired part and press ENTER.

    6. The part will now be selected and you must now choose what to do with the replaced part. The options are:

      1. Returned to Stock

        The old part will be put back into stock. A return sheet is printed, part must be put back instock. The cost is not added to production.

      2. Returned to Supplier

        This option returns the faulty part back to the supplier. This creates a Supplier Return (SRT) document with a reference to this change. The cost of the part will not be added to the production as the supplier will carry this cost.

      3. Scrapped

        This option creates a Stock Correction (SAW) document and the part is scrapped. The cost of the part being scrapped will be added to the cost of the production.

    7. Click the Change part icon to open the Change LCM Part popup.

    8. Press ENTER on line to select Lot. This will add the part to the To be replaced with field.

    9. Choose what to do with the replaced part in the Replaced part to be field. Below you are presented with four fields which requires information concerning the change, the reason for it and what to do with the replaced part.

      1. The Create QAR-field ask you if a Quality Assurance Report (QAR) document is to be created with a reference to the change. You may choose YES or NO, based on your use of QAR documents.

      2. The Caused By field gives you the option to point to where the fault lies, which is either with the supplier or the production.

      3. The Reason for Change field is a freetext field where an explanation must be entered.

      4. Enter the destination stock location for the replaced part in the Stock Location field. This field will be pre-filled with a default destination if you have a stock location (STL) defined as default stock location when part is changed in LCM in the Stock Location Details area in the STL application.

    10. Choose if a QAR document is to be created in the Create QAR drop down menu.

    11. Enter a Caused by option.

    12. Add info on the reason for change.

    13. Click the Confirm button to confirm part change. This takes you back to the LCM document and you will see the Part Change: Picking in progress icon. Information regarding the change can be seen in the Replacement column.

    14. Click the Part Change: Picking in progress icon, which will take you to the Pick Goods application.

    15. Proceed with the picking process by entering the desired quantity and click the Confirm button at the bottom. If you use the Pick All button you will not need to click Confirm.

    16. You will now return to the LCM document which is now updated with information regarding the change and who made it under the Replacement column. A deviation sheet is made in case of scrapping and a print list for the part to be replaced, which will be added to a pick list.

    17. Press the Picking in Process icon (you must wait until this appears or refresh the window) to start the picking process to get the desired part from the warehouse. Press OK on the confirm picking window which will appear.

    The radio button called History gives you the option to see the history of the part changes, with any changes entered.

    Scrapping parts

    In situations where you will need to discontinue a production, it is possible to scrap a kit and return the parts back to stock. With a Production Work Order (PWO) in ST:5 it is possible to scrap one or more kits.

    1. While in the PWO, open the LCM Documents tab to view the Life Cycle Management (LCM) document(s) related to the production.

    2. All information regarding the production is stored in the LCM documents. Press F12 to open the action menu and select Start Scrapping.

    3. A window displays where you must choose the LCM you wish to scrap.

      • If the PWO is a batch, you will be notified of this in this step. Return to the PWO and use the Split Item icon to the right to split the batch into units. It is not possible to scrap if the quantity is above 1.

    4. You can specify the reason for scrapping in the drop down list. The contents of the drop down list, the reasons, are specific to every company. Open a helpdesk ticket to add scrapping reasons for your company

    5. The PWO will now receive ST:6 and a message stating that scrapping is in process. Select F12 and select Scrapping.

    6. Choose the quantity you wish to scrap or release in the Release column for each item. Click Scrap & Return to Stock when you are finished.

    7. The PWO will now receive ST:9 and the parts are returned to stock, or scrapped, depending on your choice.

    Rework

    Rework is used in situations where an article needs to be modified. Rework may be performed on both purchased and produced parts, in addition to single part replacement in completed sub modules.

    There are certain settings that you will need to set:

    1. PartChangeCostID must be defined in ADC and must be specified, format: CST/nnnnnn.

    2. ProductPartChangeSupplierAccount must be specified, format: SUP/nnnnnn.

    3. ReworkOperationID must be specified, format: OPR/nnnnnn.

    There are certain criteria that needs to be fulfilled before a rework can be performed on a product:

    1. The product needs to be registered to stock and free for the rework process.

    2. The product/sub to replace part within must have a Life Cycle Management (LCM) document related which again needs to be a part of the part list tree.

    Perform Rework with quantity more than 1, no parts to be changed
    1. Find the Goods Reception (SSA) document with the product you want to rework. Note: the article needs to be entered into stock.

    2. Enter the SSA item you want to rework. Check that the article is not locked in other processes using the FreeQty field which states how many articles are free.

    3. Choose the Rework Product option in the context menu. This opens a popup with a list of LCM documents and serial numbers of the free articles.

    4. Choose the revision you want the product to be reworked to in the drop down menu at the top of the popup (if no new revision exist, you should create one before starting this process). Use the checkboxes in the item lines to choose which product(s) you want to rework. Click the OK button when finished.

    5. A new rework Production Work Order (PWO) has been made and is available in the PRODPLAN menu. Type PRODPLAN in the program field to enter the menu, and choose the folder Production. You may also find the PWO using the Stock Assignment Register (SAR) icon in the SSA item line.

    6. Highlight the desired PWO and press ENTER. The new revision is stated in the revision field.

    7. Pick the parts and start the production as a normal production process. Click the Production Complete button when finished.

    8. After the production is finished, use the F12 option Forward to stock to add the reworked product(s) to stock.

    Perform Rework on single quantity where parts needs to be replaced
    1. Follow the above steps 1-6.

    2. Pick the parts and start the production as a normal production process.

    3. Enter the related LCM from the PWO. Here you will find the article in the part list as an item line.

    4. Enter the product LCM. You can use the link in the Lot/Heatno column. You will now see the different parts in the LCM partlist.

      • The notification on the top of the screen tells you how many levels you have reached in the subkit(s).

    5. Click the Replace Part icon, which looks like two overlapping papers. This opens the Change LCM Part popup which lists the available SSA documents where the part is registered. Highlight the one you want to change and press ENTER.

    6. Change the part as you would normally perform a part change. Click Confirm when you are finished.

    7. On the item line, click the clipboard icon called Part Change: Picking in progress and confirm.

    8. Return to the PWO. You can use the link next to the ProdOrder field. Click the Production Complete button when finished.

    9. After the production is finished, use the F12 option Forward to stock to add the reworked product(s) to stock.

    Customer Deviation repair

    The Repair application is available in all Customer Deviation (CDV) documents where certain criteria is met, such as the correct Customer Deviation Code (CDC). The application is accessible through the repair icon in the top right corner. This application is used to keep track of the repairs performed, or to be performed, on a article in the deviation process.

    Product information

    This area, located in the top left, show all details regarding the article the deviation has been based on, including the customer and status.

    Work Log

    This log is used to register all actions taken in the repair process. This field will also mirror all information entered into the Description field in the main CDV document, with identifier and time stamp (if the plus-icon is used).

    Repair information for service report

    This field is a free text field where entries will show up in the service report.

    Below there are several fields where the error category is stated, in addition to repair date and an estimate on when the repair ends.

    Repair document

    The Repair Document area contains information regarding the warranty of the article, which parts the article contains (if it is a kit) and the work performed in the Work and Extra costs area.

    LCM Parts

    This area shows the LCM part list where parts can be changed and all information regarding the parts.

    Complete a CDV Repair
    1. When the CDV has been created, with the proper deviation code(s), and in ST:1, you can enter a description of the deviation and the steps to be taken in correcting the deviation

    2. Press F12 and choose the option Forward to Supplier.

    3. Then press F12 and choose the option Goods Received from Customer when the goods have been received. Register the part received in the system.

    4. Click the Repair App icon to enter the Repair view.

    5. Press F12 and choose the Start Repair option. A repair COA (Sales Order - Customer Owned Returned Goods) will be created.

      1. Make the necessary changes and repairs on the product. When the part has been changed, you will see the change in the Repair Document folder with all necessary information.

      2. Press F12 and choose the option Goods Repaired. Confirm by clicking OK.

    6. The CDV will move on to a further status based on the deviation code chosen.

    If needed, you can press F12 and choose the option Service Report to get a complete report regarding the repair process.

    Warranty

    Warranty is when a supplier or producer of an article agrees to repair or replace the article in case of breakage. The warranty is usually confined to a fixed period, such as 6 months or a year. Warranty may be set on Product (ART), Customers (CUS) and Shipping Advice (CSA) items and the longest period of these two will be the actual period used in the Customer Deviation (CDV) document.

    Set warranty on Product (ART)
    1. Locate the ART you want to add a warranty period to.

    2. Click the Misc folder and locate the Warranty field at the bottom.

    3. Enter the number of months you want the warranty to be active. This warranty period will now be active on this ART.

    Set warranty on Customer (CUS)
    1. Locate the customer you want to add a warranty period to.

    2. Find the warranty field in the lower right corner in the Main Data folder.

    3. Enter the number of months you want the warranty to be active. This warranty period will now be active on this customer. This warranty period will be available to see in the CSA item using the function View warrantydate, which is found under the menu option Inspects and views.

    Set warranty on Shipping Advice (CSA) item

    Warranty may be viewed, set or edited on the Shipping advice (CSA) item using the action menu option View WarrantyDate. Using this function will present an address field where the end-date of the warranty can be entered. This information is inherited to the CDV and sets the warranty to No or Yes. If no warranty is set on the customer document, the default in CDV will be no warranty. The warranty needs to be set manually in these instances.

    Warranty on CDV

    If no warranty period has been set on ART or CUS, or inherited from the CSA, the warranty can be set manually on the Customer Deviation (CDV) document in case of warranty repair or replacement. This is done after creating the initial document in the Warranty dropdown menu to the right in the document. Choose either Yes or No, and then who is responsible for cost in the Type of Repair dropdown below. A warning sign will appear if there is a discrepancy between the warranty period on the source document compared to the CDV.

    Documentation

    Requirements regarding the documentation are getting stricter and more comprehensive. The documentation process may be defined as the process where necessary documentation is retrieved throughout the life span of the production. This may be product approvals, certificates or user manuals.

    This process may result in

    1. Documentation administration.

    2. Documentation is retrieved for internal purposes.

    3. Documentation is retrieved for external purposes.

    The requirements regarding documentation in production are strict, and one might say that one shipping container of goods creates two shipping containers of documents. Documentation needs to be managed during a production run, whether it be product approvals, certificates or user manuals. If a product is a structure of different parts, the different part will also need their own unique documentation. In addition to this you also have documentation relating to the different versions of products.

    After documentation has been managed for the parts and products, the documentation for the operations and processes also needs to be managed. Operators need to document their skills, machines need documentation regarding certificates of approval and operations need to be documented with user manuals and operation routines.

    When a production is finished it is also necessary with document management. The product needs documentation concerning testing and approval, serial numbers, measuring certificates and other relevant information.

    Tasks related to this process

    1. Uploading documentation

      Documentation following purchased, modified or produced goods need to be uploaded to the system.

    2. Connecting documentation

      Documentation uploaded to the system needs to be connected to a relevant element.

    3. Print documentation

      Documentation needed in print needs to be filtered and printed.

    4. Selecting documentation

      Documentation to be included in documentation packages needs to be selected.

    Settings for Production- Documentation

    Setting name

    Description

    Activate Measure class "Dimension"

    If setting is 'ON - Set Measure class "Dimension" active

    Activate the use of a measurement forms (MSR)

    If setting is o'ON' - functionality for using Measurement Forms (MSR) is activated

    Required approval on Measure documents

    If setting is 'ON' - New FAI/KCI Measure documents will need approval as default.

    Show Date Column on Measure documents

    If setting is 'ON' - Date column will show on Measure Documents.

    Show Ref Column on Measure documents

    If setting is 'ON' - Ref column shows on Measure Documents.

    Show Tool Column on Measure documents

    If setting is 'ON' - Tool column shows on Measure Documents.

    Show Verified by Column on Measure documents

    If setting is 'ON' - Verified by column shows on Measure Documents.

    Third Country Origin limit in percent

    Value in this setting is the limit in percent for Third country origin parts value of a product. If the Third country origin product value is less than given percent of sales price in Shipping Advice (CSA), the product origin will be the same as country of the Company. By using the action 'Third Country Cost' on a Shipping Advice on a Product with Type= K*, you find the LimitPct from this settings.

    Set and edit project numbers

    It is possible to add project numbers on specific items in customer documents (COA / CSO). You may also set a project number for the entire item collection.

    1. Enter the Project (PRJ) application and create a new project, if not already existing.

    2. Enter the customer document of choice.

    3. Press F12 to open the action menu and choose the option Update project on all Items.

    4. This opens a popup where you may choose among the projects defined in the PRJ application. Choose the desired project and press ENTER.

    5. All items will be updated with the project number

      • This may be inspected by entering the item in question and clicking the AccNo icon. The project number is found in the PrjNo field.

    6. This project number will follow the order through the system.

    This project number will be visible in Production Work Orders (PWO), inherited from the customer documents, under the Project field.

    Update/edit the project number

    While in PWO / PRODSSA it is possible to change the PrjNo using the F12 option Update project on all Items. To delete the PrjNo, use the F12 option Remove project from all items.

    The project number will also be visible in the different folders in the PRODPLAN application and can be filtered using the filter field.

    Measuring Tools (MET)

    The application Measuring Tools (MET) contains all measuring tools, including discontinued. This application enables you to create new measuring tools, create purchase orders for measuring tools, reporting or creating a service order for measuring tool service.

    Creating a new measuring tool
    1. Write MET in the program field and press ENTER. This opens the Measuring Tool Menu, where all the different measuring tools are listed.

    2. Click the Define New Tool Type button. This opens a popup where you can define your new tool. Class is pre-filled in with CLASS=WT, which is the measuring tool class. Fill in the necessary information:

      1. Part: name of the measuring tool

      2. Mfr: name of the manufacturer

      3. ProdGroup: classification of the tool

      4. Text: description of the tool (not mandatory)

    3. Click the Submit button when finished. You will now see the measuring tool in ST:1.

    When all information is registered on the tool, use the context menu item Set to ST:4 (Ordinary article).

    Purchasing measuring tools

    To purchase measuring tools, it needs to be registered in RamBase, with CLASS=WT and in status 4. With these criteria filled, you can start the purchasing process from the Measuring Tools application. Click the Order new tool button and create a Supplier Purchase Order (SPO) as normal.

    Register a new measuring tool to stock

    There are two methods of registering a measurement tool to stock. The first involves creating a goods reception on an ordered tool and the other is to create the the goods reception document manually (SSA). The document which represents the tool is a Life Cycle Management (LCM) document with DOCTYPE:MET. To create this document, it is the same procedure whether you are creating the goods reception document manually or through purchase.

    A criteria for the creation of the goods reception document is that it has a serial number registered. To check this, enter the item and use the F12 menu option View Serial Numbers. If there are no serial number, it must be registered. This can be done either as a single update, or more common, by a multiple update.

    When the serial number is registerd, return to the item view and use the F12 option Create LCMs based on SNO table, which will create LCM documents for the serial numbers on this item.

    All these new LCM documents will receive DOCTYPE=MET and will not be listed in the LCM menu. These LCMs will be treated as MET, and will be available in the MET menu.

    Reporting

    There is a button called View Report, visible in the top right corner of the Measuring Tools (MET) application. Clicking this will open the measuring tools report, with any restrictions set in the MET menu.

    If you highlight one of the item lines and press ENTER, you will enter that specific measuring tool. This report can be scheduled to be delivered daily/weekly/monthly on either email or print.

    Measuring tool

    Choose a measuring tool in the menu, or report, highlight the item line and press ENTER. This will take you to the specific measuring tool.

    Here you can inspect or add information regarding the measuring tool:

    1. QAR-quality document

    2. Calibration reports/certificates (attachments in the Notes and Attachments function)

    3. Option of creating a calibration job (CSO)

    4. Information regarding the tool (MFR, prodgroup, etc.)

    5. Serial number

    6. Location

    7. Past/next calibration date

    8. Picture of the tool

    Creating a calibration order

    On the measuring tool view, you will find a button called Create New Calibration Service. Clicking this will open a new popup where you can add customer and currency. After clicking the OK button, proceed in the same way as when making a Service Order (CSO).