iScala 2.3 SR1 Manufacturing - scalabruk.se Manufacturing.pdf · iScala Advanced Manufacturing • Extends iScala Manufacturing – Larger site support • Multi-threaded calculations

Presented by:

iScala 2.3 SR1 Manufacturing

Robert SinfieldRobert Sinfield

Sr. Manager, Product Marketing

iScala Manufacturing Products

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iScala User Group Meeting © 2008 Epicor Software Corporation

Advanced ManufacturingAdvanced Manufacturing

iScala Advanced Manufacturing

• Extends iScala Manufacturing

– Larger site support

• Multi-threaded calculations on x32 or x64 bit servers

• Net change to only calculate the changed data

– New Business Processes– New Business Processes

• Plan for multiple production plants within a single iScala company

– Group warehouses for matching supply and demand

• Near real-time update of manufacturing and purchase needs

• Graphical action screen to improve usability

– Drill down to execute with a single click


Multi-Plant MRP – Example (1/5 )

Multi-Plant MRP – 1 iScala Company

MRP GRP: Plant 2MRP GRP: Plant 1

WH: 2001

Raw Materials

WH: 2003

Finished Goods

WH: 9001

Spare Parts

WH: 1001

Raw Materials

WH: 1002

Semi Finished Goods

WH: 1003

Finished Goods

MRP Groups can be used to support true Multi-site / plant MRP. Warehouses within a plant can also be excluded from the MRP calculation – i.e.

not included in the MRP Group



Several MRP Groups can be defined within the Advanced MRP module. Warehouse groups can be defined to match the actual

warehouses within a plant.

Plant 1 is on the East Coast of Sweden and Plant 2 is on the South West Cost

of Sweden. There is over 500kms between each warehouse.

Raw Materials in the warehouses at plant 1 cannot be used in the MRP calculation for plant 2 for today…



A Warehouse can only be assigned to 1 warehouse group

for the MRP Calculation.

The Warehouses 2001 and 2003 are included in

the Warehouse Group for Plant 2.



Scenario:

Plant 1 – Capacity

• Manufacturing Capacity 5,000

Sales Order Demand 10,000 units

• East: 4,000 (Plant 1)

• West: 6,000 (Plant 2)


• Manufacturing Capacity 3,000 units Manufacturing Capacity 5,000

units per week

• Raw Materials on hand for

4,000 units

• Semi-finished Goods 1,000 units

• Finished Goods on hand 1,500

units

Manufacturing Capacity 3,000 units

and 1,500 widgets per week

• Raw Materials on hand for 2,000

units

• Spare Parts on 3,000 widgets

• Finished Goods on hand 700 units



Scenario 1:


• Plant 1 will be able to meet the

Sales Order Demand 10,000 units

• West: 4,000 (Plant 1)

• East: 6,000 (Plant 2)


• Plant 2 will require two weeks to Plant 1 will be able to meet the

demands for the East within 1 week

Plant 2 will require two weeks to

meet the current Sales demands

The demand requirements can be calculated separately for each plant using the MRP warehouse

groups giving a more realistic view of the organization’s ability to meet the customer demands:

i.e. 2 weeks to meet total demand instead of 1 week when considering total capacity across both Plant 1 &

Plant 2.


MRP step 1. Collect MRP data to work file

Advanced Manufacturing – Concept

Calculate automatically when data is changed

Manufactured items calculated, Purchased retrieved from item file

Move parts of calculation to server

Low Level Code Calculation (can be run at different time as the MRP).

Lead Time Calculation (can be run at different time as the MRP)

MRP step 3. Copying calculated results to regular tables.

MRP step 2.

Calculation step

Full Regeneration Only



MRP step 2.

Calculation step

Net Change or full Regeneration


Advanced Manufacturing New Features (1/6)

• Server based MRP calculation (unattended)

– Multi-processer calculation triggered by;

• Manually from menu, by an Event or by a Schedule

• Net change MRP• Net change MRP

– Recalculation of items for which;

• Planning or on-hand balance has been changed

– Controlled by a checksum

• Stock Item Setup, bill of material, routings, etc. has changed since last MRP.

• Parent item has been recalculated



• Low level code calculation excluded from MRP

– Instant low level code calculation

• Lead time calculation excluded from MRP

– Safety stock lead time introduced.

– Manual calculation



• Stored MRP selections (00-99)

– Enter/adjust MRP selection

– Date ranges as offset from system date

• Calculation by MRP groups - Warehouse collections

– The warehouses included in a MRP group will be consolidated during calculation.

– Warehouses not included in any MRP group will not be considered by MRP. (Non-nettable warehouses)

– MRP calculation per warehouse. (one-to-one relationships between warehouse and MRP group)

– MRP parameters at Stock Item/MRP group level (overrides Stock Item MRP parameters)



• Pegging

– Applies to all lot sizing techniques.

– MRP links demands to their replenishment.

– Pegging links available from action screen, snap search queries.

• Consider allocated quantity

– Controlled by parameter

– On hand balance and need is reduced by the allocated quantity.

– No effort to link the on-hand quantity to a certain need.

• Consider locked batches




• Priority for lead time of work order proposals.

– When fixed lead time shall be used (feature 231)

• Non zero MRP lead time.

• Lead time one level

– When fixed lead time not shall be used (feature 231)– When fixed lead time not shall be used (feature 231)

• Non zero MRP lead time.

• Dynamic lead time via calculation of routings. (if routings exist)

• Lead time one level

• Days before/after the need to search orders.

– MRP will search for existing orders within the date interval



• Forecast segment as warehouse


– Segment is validated against warehouse table, query support.

– Segment selection is disabled and is replaced by warehouse (MRP group) selection.

– Forecast consumption per warehouse

• Uses same MRP tables as standard manufacturing

– Re-use of existing reports

– "Invisible upgrade"


MRP/MPS/SRP Action Lists

• Grid based view of all action tasks

– Multiple filters to select tasks quickly

– Right-click access to detailed screens

– Can resolve task directly and return to action list


Action List – Configuration (1/11)

Specify ID and Description, press adjust to continue



All selection values entered on this tab except for warehouse, relate to the stock item master settings.



The values specified on this tab apply to work orders processed by MRP or MPS



The selection values entered on this tab apply to purchase orders processed by MRP or MPS



These selection values apply to work order proposals created by MRP



These selection values applies to replenishment proposals created by MRP



Specify the initial sort order of the lines loaded into action screen. UI-sorting is enabled



Specify parameters that will apply when proposals are released.



Define visible columns and the order in which they will appear in the grid. Frozen columns are not affected by horizontal scrolling.



Define what extended information will be included in the search



Press ok to load action screen using the selected view...

Press ’OK’ to save.Press ’OK’ to save.


Action screen – Replenishment (1/22)

Use the type filter to only display orders or proposals of a certain type. Select ”All” of a certain type. Select ”All” to display all lines initially selected



Use the action filter to only display orders or proposals display orders or proposals with a certain action



Use the message filter to only display work order proposals with a message



Right click the row header and select ”accept the proposed action” from the menu.



To adjust the proposal, right click the row header of the proposal and select ”Adjust more proposal data”. The proposal adjustment screen will appear



Select supplier by a double click. The price will be set with respect to the price/discount matrix.



There is currently no integration with purchase contracts, this tab is for information only.



To split a proposal, right click the row header of the proposal and select ”Split proposal” from the menu.



Specify quantities for the proposals, the total quantity can be different than the original quantity.



To display MRP calculation, right click the row header and select ”Show MRP calculation” from the menu. This menu item is disabled for MPS lines.



Advanced MRP will save and display the balance at the time for calculation.



To view the pegging against an order or proposal, right click the row header and select ”View relations to demands” from the menu.



The order/proposal will be displayed together with the demands MRP considers to cover with the order/proposal.



To enter text lines, right click the row header for a proposal and select ”Enter text lines” from the menu.



The text lines will be updated to the order when the proposal is released.



To view all the fields for the line, right click the row header and select ”Display all line data” from the menu.



To display the extended information, right click the line and select ”Show extended information”.



The following extended information can exist:

• Life cycle information (on hold, controlled distribution)

• Item exist on purchase contract

• Work order started

• Quality control on delivery iScala User Group Meeting © 2008 Epicor Software Corporation


Release the proposal by right click the row header of the proposal line and select ”Release proposal” from the menu.



And finally, the list of created orders is printed



The type is changed with respect to the selected release type, order number reference is updated.



It’s possible to view or adjust the order. Right click the row header and select View- or Adjust order.


Action screen - Manufacturing

Adjust a proposal by right click its row header and select ”Adjust more proposal data” from the menu.



It’s possible to release a work order proposal to a firm planned order or to a work order.

The work order proposal screen includes fields for alternate routing and scheduling code.



To check the load availability, right click the row header of the work order or the work order proposal and select ” Load availability” from the menu.



The green nodes denotes the operations related to the selected work order/ work order proposal. The other nodes denotes the load related to other work orders/proposals. Fully loaded days are denoted by red nodes.

To find the orders/proposals that loads the work centre on a certain date. Right click the node and select details.



To check the availability of the components, right click the row header and select ”One level material check” from the menu.



For work order proposals, the material available test simulation will be launched.

For work orders, the material availability test will be launched.



To enter text lines, right click the row header of the proposal and select ”Enter text lines” from the menu.



The text lines will be updated to the work order The text lines will be updated to the work order when the proposal is released.



To release a proposal, right click the row header and select ”Release proposal” from the menu. It’s possible to release several proposals by ticking the release tick boxes and then press the release buttonthe release button





When the proposal has been released, the type and been released, the type and the order number reference is updated.


Manufacturing Value PackManufacturing Value Pack

Graphical Work Order and Work Centre Planning – Configuration (2/2)

The Work Centre list allows the user to select the Work Centres to be included in

the report. The work centre code, description, type and

sub-contractor name (where applicable) are

shown.

The work centres to be included in the report are

marked using check boxes.


Graphical Work Order and Work Centre Planning – Use (1/5)

Overloaded ‘WC-dates’ are painted with pink color

Subcontractor Work Center background is painted with

blue on Gantt Chart

Work Order Planning Gantt Chart displays: Work orders, Sales

orders, MRP Proposals, Released MRP Proposals, Firmed Planned

orders, MPS Proposals.

The work centres codes are shown on the left hand

side of the screen


Graphical Work Order and Work Centre Planning

– Use [Sub-contracted Work Centers] (2/5)

Right-clicking on the Gantt Chart background, the user can see a number

of options including viewing the Sub-contractor Work Center parameters



– Use [Right Click] (3/5)

View Work centre Load is also available by right-

clicking on the Gantt Chart background,


Graphical Work Order and Work Centre Planning – Use [Double-Click] (4/5)

Double-click on an operation node, to see detailed information

related to the operation.

This screen is updated with the new field ‘Node Type’.



– Use [Roll-up Mode] (5/5)

Clicking the ‘Roll’ button provides a

more compressed

view


(standard) Manufacturing(standard) Manufacturing

Part Day (Factor) support in MPC

• Works with part days (factors)

– Factor is % of total resources

– Can be complex for WC with multiple resources

• Define a factor for start and due date

– Used internally by MPC for scheduling– Used internally by MPC for scheduling

– Shown in all MPC screens that supported a scheduled date


WO to SO Link Improvements

• Link the WO and SO logically

– Current design assumes one WO per SO

– Future enhancement may add support for multiple WO

• Display and update WO status

– WO status updated when WO is released, printed, reported, – WO status updated when WO is released, printed, reported, receipted or closed

– Lets sales staff communicate with end customer

• Security to prevent unauthorised direct update

– Permissions to control who can directly update SO line with linked WO

– If permission granted

• Warning if changing dates or order numbers manuallyiScala User Group Meeting © 2008 Epicor Software Corporation

Chain Planning Enhancements

• Possible to include or exclude queue and move time

– These often are tasks that can be done in parrallel to

production


Standard Cost Improvements

• Define a warehouse costing group

– Reflect real world

• Many iScala warehouses may be virtual representation of a single location (warehouse group)

– This release supports only 1 standard cost group

– The primary warehouse must be the default warehouse

– Once defined can only update or change the cost in the primary

– All changes copied to other warehouses in the group

• Tool to clean up old costing data

– Makes standard cost calculation faster


Standard Cost improvements

New Warehouse parameter.

Default value for parameter is “No”.

This field is Disabled for Main Warehouse as defined in the

Stock Parameter file


Enter/Adjust Stock Values

Standard Cost values cannot be using copy standard cost

of other functions

iScala 2.3 SR1 Manufacturing Enhancements © 2008 Epicor Software Corporation.

The Standard Cost values cannot be manually changed in a warehouse that is setup

to use the Standard Cost values in the Primary / Main

Warehouse


Configurable Work Order line Interval

The Work Order line interval can be defined according to the

customers needs.customers needs.


Manufacturing Application IntegrationIntegration

Manufacturing Application Integration

• Will support

– BoM in and out

– Work Order in and out

• Including new work order in (gap in older releases)

– WO release in

Updates planned for

July HF

– WO release in

– Materials issued to work order

• Now with option to report using material report number

– WO Completion

• With or without back-flushing

• Report scrap, actual quantities and actual time can be reported

– Support for using batch numbers

• Prior releases only supported batch ID


Add-on ProductsAdd-on Products

iScala Collect

Internal Movement ManufacturingPick Requisitions

Processes automated by iScala collect

Receiving

Inspection & Update

ShippingPickingSuppliers

Counting

Put AwayWarehouse

Customers

Sub-contracted

Manufacturing


iScala Collect Manufacturing

• Added to iScala Collect in release 3.40

– Picking against work orders if pick list previously printed

– Pick against stock transfer orders for sub-contracted

activity

– Receive completed goods from work centres– Receive completed goods from work centres

– Receive completed goods from sub-contractors

– Report actual WC used for in-house production


Presented by:

iScala 2.3 SR1 Manufacturing

Adam PrinceAdam Prince

Sr. Director, Product Marketing

Documents

iScala 2.3 SR1 Manufacturing - scalabruk.se Manufacturing.pdf · iScala Advanced Manufacturing • Extends iScala Manufacturing – Larger site support • Multi-threaded calculations