| # Generic Routing (tipcf3120m000) Use this session to list, select, and maintain operations of a generic routing. The generic operations constitute the generic routing for the product. A generic routing contains one or more operation variants for each operation number. During the configuration or generation process for a product variant, a variant routing originates from a generic routing. For each operation number, this variant routing contains one of the operation variants from the generic routing. For each operation variant you can define a constraint in which you record under which conditions the generic operation must be included or excluded for a certain product variant. So constraints control the translation of customer requirements to a set of operations that must be carried out to manufacture the product variant. During the product configuration or product generation process, ERP LN can calculate the average setup time, production rate, and cycle time by using a formula. To do so, define a constraint in the Generic Item - Constraints (tipcf2110m000) session, and select Parameter Substitution in the Constraint Section field. The formula must now be entered in the constraint editor that is started from the Generic Item - Constraints (tipcf2110m000) session. Related topics How to define a product model How to test the product model How to configure product variants and generate product structures PCF procedures Generic Item The generic item. The item code to be selected must be predefined in the Items - Production (tiipd0101m000) session. The item type of the manufactured item must be Generic. Routing Unit Quantity of the manufactured item on which the routing is based. With this unit, you can include very short operation times in the routing of an item. Routing Unit The unit of the routing unit. Start Operation If the operation does not follow any other operation, this field displays an indicator for a start operation. Related topics Network routings End Operation If the operation is the final operation, this field displays an indicator for an end operation. Related topics Network routings Operation The operation number is used to sequence the various operations for a generic manufactured item. This operation number is comparable with the operation number in a routing sheet for a standard manufactured item in the Routing module. With generic operations, however, several variants may be defined for each operation number. Slash Character The sequence number indicates the possibility of entering several variants for each operation number. The sequence number is also used with respect to the effective and expiry date. Next Operation If you defined a network routing, the operation specified in this field must be executed following the current operation. This field is visible if the Allow Parallel Operations in Routing check box in the Routing Parameters (tirou0100m000) session is selected. Regular routing If you do not define a network routing, the Next Operation field must be 0 (zero) for all routing operations. In that case, the operations are executed in order of operation number, for example, 10 - 15 - 20 - 40. Network routing If you define a network routing, the following conditions apply: Exactly one operation is the end operation. For the end operation, the Next Operation field is zero. The operation number of the next operation must be greater than the number of the current operation. For example, operation 40 must not follow operation 50. ERP LN does not automatically check these conditions. To check whether the routing meets the conditions, click Validate Sequence on the Specific menu. When a production order is created, ERP LN will again validate the routing. Caution! If you specified an operation in the Next Operation field, and that operation is skipped for a particular product variant, ERP LN does not automatically replace that operation with the correct operation. Instead of the operation that follows the skipped operation, ERP LN selects the operation with next higher operation number. After ERP LN generated the routing for the product variant, correct the operation sequence for the customized item or configured standard item in the Routing Operations (tirou1102m000) session. Related topics Network routings Scrap Quantity Unusable material or rejects of intermediate products, for example, because of faulty components, or products lost in cutting or sawing operations. The gross material requirements and/or an operation's input quantity must be increased to account for anticipated scrap. In the BOM, you can define scrap as a percentage of the net material requirements, which is the scrap factor, and as a fixed quantity, which is the scrap quantity. A scrap quantity is mostly used to define the amount of material that is lost every time when you start producing, for example, to test the equipment. For an operation, you can only define the scrap as a fixed quantity. Note If the Scrap Quantity and Yield on Operation check box is selected in the Routing Parameters (tirou0100m000) session, this field is filled. If the check box is cleared, scrap is zero. Related topics Scrap and yield Defining scrap and yield Yield Type Determines if and how lost products come out of production if the yield percentage is below 100%. Two yield types are available: Discrete Lost products come out of production as rejected products. Continuous Lost products disappear completely, for example, through evaporation. Note If the Scrap Quantity and Yield on Operation check box is selected in the Routing Parameters (tirou0100m000) session, this field must be filled. If the Scrap Quantity and Yield on Operation check box is cleared, this field is Not Applicable. Allowed values Possible Values Related topics Scrap and yield Defining scrap and yield Yield Percentage The yield output expressed as a percentage of its input. Note If the Scrap Quantity and Yield on Operation check box is selected in the Routing Parameters (tirou0100m000) session, this field is filled. If the check box is cleared, the yield percentage is 100. Related topics Scrap and yield Defining scrap and yield Extra Information Additional information about the task. For example, the tools to be used. Subcontracting Rate Factor The subcontracting rate factor, together with the subcontracting base rate, determines the cost of subcontracting. Subcontracting with Material Flow If this check box is selected, ERP LN supports the physical and administrative flow of material and subassemblies to the subcontractor. Related topics Overview of subcontracting Subassembly An intermediary product in a production process that is not stored or sold as an end product, but that is passed on to the next operation. For subcontracting purposes, a manufacturer can send a subassembly to a subcontractor to carry out work on the subassembly. This subassembly has its own item code defined in the Item Base Data. After work is finished, the subcontractor sends the subassembly back to the manufacturer. Also this reworked subassembly has its own item code defined in the Item Base Data. Subassembly Warehouse The warehouse from which the subassembly is sent or in which the subassembly is received. Queue Time The amount of time that an order remains at a work center before setup or work is performed on it. Average Setup Time The time required for setting up or changing over a machine before you start running the machine. Setup time can be long, for example, if you change over from using black paint to using white paint. Setup time can be short, for example, if you change over from using white paint to using yellow paint. The setup time must indicate an average of all possible setup times. By default, ERP LN shows the average setup time belonging to the task entered. If required, the setup time can be changed. The setup time is expressed in minutes and is independent of the order quantity. You can let ERP LN compute the setup time to configure a product variant. If so, you must link a constraint to this operation during which you define a formula, which will be applied during configuration. ERP LN then overwrites the value that you enter here with the calculated value. Production Rate The number of products manufactured per unit of time (hour or minute, dependent on the parameter setup). The production rate provides an alternative for recording operation times. The operation with the lowest production rate is considered the bottleneck for RPT items. Production Rate The unit that is used to specify the physical quantity time. Cycle Time By default, ERP LN shows the cycle time belonging to the task entered. It can be changed, if necessary, and is expressed in minutes. The total cycle time depends on the batch size. You can zoom to the Calculate Norm Time (tirou0230m000) session from this field. On the basis of the defined times in the norm tables, you can use ERP LN to compute the cycle time. Refer to the session Help of the Calculate Norm Time (tirou0230m000) session for more information. You can use ERP LN to compute the cycle time when a product variant is configured. If so, you must link a constraint to this operation in which case you define a formula, which will be applied during configuration. ERP LN then replaces the value that you enter here with the calculated value. The cycle time is the basis for the cycle time in the customized routing. The customized run time can be determined by parameter substitution in the Generic Item - Constraints (tipcf2110m000) session. The customized cycle time then overrules the value entered in this field. The same option is available for the Production Rate field. Production time = setup time + (batch size * cycle time) Related topics Calculating based on norm tables Calculating production rate and cycle time from a norm table Wait Time The time that an order remains at a work center after an operation is completed until it is moved to the next operation. ERP LN does not plan wait times according to a specific calendar. Planning of the wait time is based on a 7 * 24 hours week schedule. A typical example is the time required for drying after the application of paint. Move Time The time that a semifinished good is in transit from one operation to the next operation. After the last operation, the move time is the time to transfer the finished good to the warehouse. Move time is one of the lead-time elements ERP LN plans according to a specific calendar. Man Occupation for Setup The number of persons that is needed to accomplish the operation's setup. Man Occupation for Production The number of persons that is needed to accomplish the operation. You must enter the number of persons that is needed to accomplish the operation's setup in the Man Occupation for Setup field. Machine Occupation The machine occupation indicates how many machines are needed to carry out the operation. Fixed Duration An indication whether the production time is fixed, or is dependent on the order quantity. If the production time has a fixed duration, then it equals the cycle time. If it is indicated that the production time does not have a fixed duration, the cycle time is multiplied by the order quantity. For example, baking one bread in the oven takes one hour. Baking a hundred breads at once also takes a fixed duration of one hour. If this check box is selected, the duration of an operation is fixed, and its production time does not depend on the batch size.
     Production time =
    				setup time + (1 * cycle time)
Transfer Batch Less Than Production Batch The quantity or percentage of items for which an operation must be finished before you can start with the next operation. Even though an operation is not yet finished for all items in a production order, you can start the next operation for the items that are already finished. In a production environment where kanban is used, the transfer batch quantity equals the kanban size (which is the standard container, or the standard lot size). The transfer batch quantity replaces the previously used concept of overlap percentage on operation. If this check box is selected, you can start the next operation before the complete production batch is finished. You must enter a value in the Transfer Batch Quantity field, which indicates when the next operation can be started. If this check box is cleared, the next operation starts when the complete production batch is finished. If the Transfer Batch Method field in the Routing Parameters (tirou0100m000) session is Quantity, you must type a quantity in the Transfer Batch Quantity field. If the Transfer Batch Method field is Percentage, you must type a percentage. Transfer Batch Quantity The quantity or percentage of items for which an operation must be finished before you can start with the next operation. Even though an operation is not yet finished for all items in a production order, you can start the next operation for the items that are already finished. In a production environment where kanban is used, the transfer batch quantity equals the kanban size (which is the standard container, or the standard lot size). The transfer batch quantity replaces the previously used concept of overlap percentage on operation. If the Transfer Batch Method field in the Routing Parameters (tirou0100m000) session is Quantity, you must type a quantity. If the Transfer Batch Method field is Percentage, you must type a percentage. Planned Production Time The planned production time is used when you determine the average lead time and the average capacity for items with order system Planned. Planning Percentage Similar to the planned production time, the planning percentage determines the capacity requirements of planned enterprise planning orders for generic items with enterprise planning calculation. Lead Time Offset This field is only used by Enterprise Planning. When a generic item is planned, the start date of an operation is calculated by offsetting the requirement date of the generic item with the lead time offset. The finish date of the operation is determined by adding the planned production time. The planning percentage is used to determine the required work center capacity. Constraint ID The code of the constraint that applies to this operation. The process for creating the routing can be controlled with constraints. For instance, you can build a constraint that selects the operation or does not select the operation for a product feature that is linked to the item. You can also build a constraint that specifies variables in the operation, such as the cycle time and the average setup time. Task The task number that specifies the operation type. Work Center The code of the work center where the operation is performed. By default, ERP LN shows the work center code that belongs to the task entered. If required, the work center can be changed. The work center to be entered must be predefined in the Work Centers (tirou0101m000) session. Machine The code of the machine on which the operation is carried out. This field is irrelevant for a nonmachine task. By default, ERP LN shows the machine number that belongs to the task entered. The machine number can be changed. The number to be entered must be predefined in the Machines (tirou0102m000) session. Effective Date The effective date determines when the operation line is valid. The effective date is used during the execution of the following sessions: Generate Order Planning Copy Standard Product Structure to Customized Structure (tipcs2230m000) Production Orders (tisfc0501m000) Starting from the effective date: The operation time (for this operation line) is added to the lead time. The specified work center has capacity requirements. Expiry Date The expiry date indicates from which date the operation line is invalid. Backflushing If this check box is selected, hours and material are posted based on estimated consumption. Serialized items Serialized items can only be backflushed if in the Items - Warehousing (whwmd4500m000) details session the Serials in Inventory check box is cleared, and the Register Serial Issue During As Built field is Yes. In all other cases, serialized items cannot be backflushed. If the serialized item is lot-controlled, the lot from which the items are backflushed is based on the outbound method ( Last In First Out (LIFO), First In First Out (FIFO)) as is defined in the Items - Warehousing (whwmd4500m000) details session. Related topics Backflushing Overview of serialized items Count Point A count point specifies that the quantity of products to be reported as completed for a following operation does not exceed the quantity of items reported as completed for the current operation. Container A vessel used to store or move material. Container Method The shipment method how to handle items in the container. For instance, stack should be less than 10 tiers high. Container Quantity The quantity of items stacked in the container. Number of Kanbans The number of kanbans that is used in the pull system. Related topics Labels in Manufacturing Description on Kanban The description of the inter-operation kanban that serves as an identification for the kanban. Related topics Labels in Manufacturing Operation Text With the text manager you can record detailed operation texts with more information about the operation. In the operation texts, product features can be included as variables that are automatically substituted with the description of the product generator's chosen option value. If the option description is insufficiently denoted, ERP LN adds the option value to the option description. Product features must be entered with square brackets ([...]) in operation texts, as in constraint expressions. Physical Location The location where the operation is performed. Print Generic Routing Click to print the Print Generic Routing (tipcf3420m000) session. Validate Sequence Validates the values of the Next Operation field. |