Advanced Repetitive – Advanced Tools for
Managing WIP
California User Group
October 11, 2011
Santa Barbara, CA
Paul Rubin
AGENDA
Introduction
Overview of Adv Rep & WIP
Visibility & Valuation
Management / Processing
Lot/Serial Tracking & Traceability
WIP Lot Trace
Q&A
Setup
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•
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•
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•
•
•
Advanced Repetitive Enabled – 18.22.24
Item with M or L code – 1.4.7 or 1.4.17
Routing Required - 14.13.1 or 14.13.2
BOM with Operation Step - 13.5
Operation Cost Calculation - 14.13.17
Item on Production Line – 18.22.1.1
Employee created – 2.7.1
Can create location = work center - 1.1.18
Routing Maintenance - 14.13.2
Milestone & Non Milestone Operations
Must report production at milestone
All previously non milestones are backflushed at next
milestone
WIP Queues
• Input Queue
• Output Queue
• Reject Queue
Product Structure Maintenance – 13.5
Required for Adv Rep backflush
Cost Roll Ups
• Routing Cost Roll-Up – 14.13.13
• Product Structure Cost Roll-Up – 13.12.13
• Operation Cost Calculation – 14.13.17
Operation Cost Report – 14.13.19
Repetitive: Using it
Demand
Sales Orders
Gross
Requirements
Cus tom er’s
Scheduled
Requirements
Dis tribution
Center’s
Requirements
Foreca st
Schedule
Requirements
MRP
(( Menu
Menu 23)
23)
Line
Line
Sequencing
Sequencing
(Menu
(Menu 18.22.1)
18.22.1)
Master
Scheduler
Repetit
Repetitive
ive
Schedule
Schedule
Repetit
Repetitive
ive
Explos
Explosion
ion
(Menu
(Menu 18.22.2)
18.22.2)
(18.22.2.4)
(18.22.2.4)
July 1994
Sun
Mon
Tue
Wed
Thu
Fri
Sat
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2
3
4
5
6
7
8
9
10
11
12
13
14
15
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18
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21
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23
24
25
26
27
28
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30
Repetit
Repetitive
ive
Picklis
Picklistt
31
Inventory
(Menu
(Menu 18.22.3)
18.22.3)
Production
Reporting
Repetit
Repetitive
ive
Reporting
Reporting
(Menu
(Menu 18.22.4)
18.22.4)
Finished Items
Backflush
Cum
Cumulative
ulative
Order
Order
Close
Close
(18.22.10)
(18.22.10)
Processing
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•
•
•
•
•
Backflushing
Rejects
Rework
Scrap
Move
Subcontract Shipper
Backflush – 18.22.13
Rejects
Can report during backflush: 18.22.13
Can report at non – milestones: 18.22.16
Reject during Backflush – 18.22.13
Rejects can be entered during backflush transaction with up to 10 reason codes
and are included in the Qty Processed. The rejects are placed in the Reject
Operation queue indicated in Reject To Op.
Strategic Information Group
Copyright © 2007
Reject Transaction – 18.22.16
Rejects can be entered for non-milestone operations; up to 10 reason codes can
be entered by checking Multi Entry box
Strategic Information Group
Copyright © 2007
Rework
Can rework previously rejected items
18.22.17
Can charge labor and/or issue additional
components
Rework Transaction – 18.22.17
The Qty Reworked is required. You can enter rework hours and issue
additional components. However, no automatic backflushing takes place.. If
you used additional components, check Modify Backflush. You can modify
the default Operation an Queue reworked items to be moved to.
Strategic Information Group
Copyright © 2007
Rework Transaction cont.
Select items which were used and appropriate quantities
Strategic Information Group
Copyright © 2007
Move Transaction – 18.22.19
Move Transaction (18.22.19) transfers quantities from an operation’s
output queue to the following operation’s input queue. For the final
operation, items are moved to finished material inventory. Must be used with
Subcontracting PO’s where serial or lot number required on inventory receipt or
when final operation item are reworked.
Strategic Information Group
Copyright © 2007
Sub Shipper Maintenance – 18.22.5.5
Moves item from output queue of previous operation to
input queue
Sub Shipper Issue – 18.22.5.11
Enter in Ship-From (Site) and Shipper ID; this process any
previous non milestone operations and moves the quantity to
the input queue of the subcontract routing operation.
Scrap
Can record during backflush: 18.22.13
Can record out of queue 18.22.18
Scrap Transaction – 18.22.18
Use Backflush Transaction (18.22.13) for most of your scrap reporting. It backflushes the
scrapped units and records all costs at the operation. Use Scrap Transaction (18.22.18) to
scrap or remove quantities from any queue of an operation without backflushing.
Strategic Information Group
Copyright © 2007
WIP Inventory Management
See inventory in operation queue’s in
WIP Status Inquiry (18.22.13) or WIP Status Report
(18.22.4.11)
See WIP Valuation Report (18.22.4.13) for inventory $
Can adjust WIP inventory in 18.22.21 (change quantities
in one of the queues)
WIP Status Report – 18.22.4.11
The WIP Status Report shows the quantities and activities in the various queues
Strategic Information Group
Copyright © 2007
WIP Adjust Transaction – 18.22.21
Use WIP Adjust Transaction (18.22.21) to adjust quantities at an operation’s
input, output or reject queues. Change to correct quantity. Similar to cycle
count transaction.
Strategic Information Group
Copyright © 2007
Lot/Serial Traceability
* Required if Lot/Serial field is L or S in 1.4.5
* Modify Backflush frame appears in 18.22.13 and
requires lot/serial number to process the transaction
- This is for components; receipt screen for parent
* Serialization traceability requires one for one
* Work Orders vs. Advanced Repetitive
* Lot Trace Reports
- Lot Transactions by Date
- Lot Actual Bill Inquiry
WIP Lot Trace
* Part of Pro Plus Functionality
* Ability to track lot/serial numbers within a cum order or
work order including multiple lots at subcontractor
* Flexible registration to track what components and what
operations
* Cannot be used to track at Non Milestone Operations
* Control of combining or splitting lots
WIP Lot Trace - continued
* Can restrict the size of lots
* System assigned lot/serial numbers from Number
Range
* Can trace lot references
* WIP Inventory Reports
* WIP Traceability Reports
WIP Lot Trace Setup
Registering Routing Exceptions
Registering BOM Exceptions
Using WIP Lot Trace
* Destination Work Center and Machine
* Recording Lot Input and Issue Data
Destination Work Center and Machine
WIP Lot Input and Issue Data
WIP Lot Output and Receipt Data
Reporting Reject Data
Reporting Scrap Data
Additional WIP Lot Windows
* Recording Rework Data
* Recording Lot Move Data
WIP Lot Reports
* WIP Lot Inventory Status Report
* Item Lot Ship Transaction Report
* WIP Lot Convert Transaction Report
* WIP Lot Non-Convert Transaction Report
* WIP Lot Inquiry
* WIP Lot Where Used Report
* WIP Lot Actual Bill Report
Inventory Status Report
Summary
Advanced Repetitive provides for tracking of WIP
inventory. Allows rejects, rework and scrap.
WIP Lot Trace provides additional functionality for traking
and managing lots within a cum order or work order.