| # Routing Operations (tirou1102m000) Use this session to maintain operation data by manufactured item and/or by routing. A routing consists of one or more separate operations, which are carried out in succession. This data is used to compute order lead times, to plan production orders, to calculate cost prices, and so on. Performance aspects The settings in this session could affect system performance and database growth. For more information, refer to Micro routing. Related topics Place and functions of operations To enter a routing Microrouting Scrap and yield Production order lead-times (transfer batch quantity) Manufactured Item The code of the manufactured item. If this field is empty, the routing is a standard routing. An item code for a manufactured item must also be entered in the Items - Production (tiipd0101m000) session. If you want to define routing operations for a standard routing, you must leave this field empty. Related topics Standard routing Order Lead Time The production time of an item expressed in hours or days, based on the lead time elements as defined in the routing operations. You can determine the order lead time by clicking Update Lead Time... in the Specific menu of this session, or clicking Update Order Lead Time in the Items - Production (tiipd0101m000) details session. Note The value of this field is calculated based on the routing data entered in this session. The lead time, as based on the cycle time and other values, is multiplied with the economic order quantity specified in the item ordering data. Related topics Production order lead-times (transfer batch quantity) Routing The sequence of operations required to manufacture an item. For each operation, the task, machine, and work center are specified, as well as information about setup time and cycle time. Routing Unit The quantity of the manufactured item on which the routing is based. A routing quantity enables you to include very short operation times in the routing of an item. Example
Routing quantity | 100
Cycle time | 60 minutes
In a 60 minute time span, 100 items are produced. Consequently, the operation time of one item is 0.6 minute. Inventory Unit The unit of measure in which the inventory of an item is recorded, such as piece, kilogram, box of 12, or meter. The inventory unit is also used as the base unit in measure conversions, especially for conversions that concern the order unit and the price unit on a purchase order or a sales order. These conversions always use the inventory unit as the base unit. An inventory unit therefore applies to all item types, also to item types that cannot be kept in stock. 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 One of a series of steps in a routing that are carried out successively to produce an item. The following data is collected during a routing operation: The task. For example, sawing. The machine used to carry out the task (optional). For example, sawing machine. The place where the task is carried out (work center). For example, woodwork. The number of employees required to carry out the task. This data is used to compute order lead times, to plan production orders and to calculate cost prices. / The sequence number of the operation. This number is based on the effective/expiry dates, and is used to distinguish between operations. The effectivity and expiry date for operations are used in: Enterprise Planning Cost Price Calculation Shop Floor Control Next Operation If you defined a network routing, the operation that is specified in this field must be performed after 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 performed 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 0 (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, on the Specific menu, click Validate Sequence. When a production order is created, ERP LN validates the routing and stops the process if the routing is incorrect. Related topics Network routings Task Data Task An activity to manufacture or repair an item. For example, sawing, drilling, or painting. A task is carried out on a work center, and can be related to a machine. Work Center The default work center where the task is carried out. You can select another work center. Machine The machine on which the operation is performed. Operation Lead Times Queue Time The amount of time that an order remains at a work center before setup or work is performed on it. Related topics Production order lead-times (transfer batch quantity) Queue Time The time unit in which your express the queue time. If the time unit is Hours, you can enter fractions. If the time unit is Days, ERP LN rounds the entered values to an integer. Related topics Production order lead-times (transfer batch quantity) Average Setup Time [Min] 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. Production Rate The number of units for which the task can be performed per unit of time (per hour or per minute, depending on the Production Rate Time Unit field in the Routing Parameters (tirou0100m000) session), for a combination of an X-axis value and a Y-axis value from a norm table. You can compute the production rate in two ways: If the Use Production Rates check box in the Routing Parameters (tirou0100m000) session is selected, you can compute the production rate by zooming to the Calculate Norm Time (tirou0230m000) session. You can enter a value in the Cycle Time [Min] field, and compute the production rate by clicking the Calculate Rate button. Note If the Use Production Rates check box in the Routing Parameters (tirou0100m000) session is cleared, you cannot maintain this field. Related topics Calculating based on norm tables Calculating production rate and cycle time from a norm table / The unit that is used to specify the physical quantity time. Cycle Time [Min] In ERP LN, the time between completion of two separate units of production. For example, the cycle time of motors assembled at a rate of 120 per hour is 30 seconds. The cycle time is also equal to the time that a product stays in one position on a assembly line, or the time that an operation is carried out on an item in a work station (excluding setup time). You can zoom to the Calculate Norm Time (tirou0230m000) session to calculate the production rate. Related topics Calculating production rate and cycle time from a norm table Calculating based on norm tables 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. Related topics Production order lead-times (transfer batch quantity) 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. Related topics Production order lead-times (transfer batch quantity) Execution details Man Occupation for Setup The number of persons required to accomplish the operation's setup. Enter the number of persons required to accomplish the operation in the Man Occupation for Production field. Man Occupation for Production The number of persons required to accomplish the operation. Enter the number of persons required to accomplish the operation's setup in the Man Occupation for Setup field. For more information about changing this field, refer to the session Help of Routing Operations (tirou1102m000). Machine Occupation This field indicates how many machines are required to carry out the operation. For more information about changing this field, refer to the session Help of Routing Operations (tirou1102m000). This field is enabled when you have defined a machine for the selected work center in the Tasks (tirou0103m000) session. 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. Effective Change Order The change order (CO) that defines the effective date of the operation. Click ... to start the Change Order (dmchm0150m005) session. Backflushing If this check box is selected, the materials and/or hours used during the operation are automatically backflushed after an operation is reported as complete. 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 Effective Date The date when the validity period of an entity starts. In the case of effectivity control the reference date is checked against the effective date. If the reference date is greater than or equal to the effective date the configuration entity is valid. Related topics Effective date of materials and operations Count Point If this check box is selected, the operation is a count point. in process by CHM If this check box is selected, the operation is under change management control. If a change order is linked to the operation, and the change order is not approved yet, ERP LN selects this check box. Change management keeps track of the effective and expiry dates of an operation for a defined procedure. DMS on Completion If this check box is selected, direct material supply (DMS) planning will be run when the operation is reported complete. Related topics Direct material supply (DMS) Standard Configuration If this check box is selected, the routing operation is part of an item’s standard configuration. The costs related to the routing operation are included in the standard cost price. If the Standard Configuration check box is cleared, the routing operation is not part of an item’s standard configuration. The costs related to the routing operation are not included in the standard cost price. The Standard Configuration check box in combination with the setting of the Valid check box in the Exceptions (tcuef0105m000) session indicates whether the routing operation is used for a specific effectivity unit. If the Standard Configuration check box is selected, and the Valid check box is cleared for an exception linked to the routing operation, the routing operation will be omitted for a specific effectivity unit or requirement. If the Standard Configuration check box is cleared, and the Valid check box is selected for an exception linked to the routing operation, the routing operation will be added for a specific effectivity unit or requirement. Note If the routing operation has exceptions attached, but you do not want to use the exceptions, for example, for selling spare parts, or for an end item which is not unit-effective, then you can clear this check box. Related topics Overview of unit effectivity Exceptions Present If this check box is selected, exceptions are linked to this routing. In other words, the routing is unit effective controlled. If you delete the routing's exceptions in the Unit Effectivity module, the check box is cleared. Note You cannot define exceptions for a standard routing. The Standard Configuration check box and the Exceptions Present check box cannot be selected at the same time. Related topics Overview of unit effectivity 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. 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. Allowed values Yield Type Yield Percentage The usable output from a operation expressed as a percentage of its input. Example 1: An operation in the production process for light bulbs has a yield of 98%. So, out of every 100 light bulbs produced, 98 are good on average. The remaining light bulbs are faulty, and will therefore be rejected. Example 2: Steel wires are twisted together to produce a steel cable. Due to the twisting, the cable is 10% shorter than the wires from which it is produced. So, the yield is set to 90%. Extra Information Use this field to enter additional information. Subcontracting Rate Factor The subcontracting rate factor, together with the subcontracting base rate, determines the cost of subcontracting. The value of this field depends on the setting of the calculation method for the subcontracting rate as recorded in the Subcontracting Rates (ticpr1160m000) session. If this field reads Operation Rate, the following construction is possible. You may depart from a base rate for subcontracting and further specify that base rate for each operation line. Example Subcontracting rate is 100 Subcontracting rate factor is 2 The total cost of subcontracting is 200 Expiry Change Order The change order (CO) that defines the expiry date of the operation. Click ... to start the Change Order (dmchm0150m005) session. Expiry Date The date on which the operation line is no longer valid. The latest possible expiry date is 19 January, 2038. If you do not enter an expiry date, 01/19/38 is automatically displayed. Related topics Effective date of materials and operations Transfer Batch Less Than Production Batch 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. Related topics Production order lead-times (transfer batch quantity) Activity You can zoom to the Activities (tipcs4101m000) session to select an activity. An activity can be an operation in network planning. 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. Note Labels in Manufacturing Description on Kanban The description of the inter-operation kanban that serves as an identification for the kanban. Physical Location Place where the operation actually takes place. Copy... Starts the Copy Routing (tirou2201m000) session in which you can copy operations from one routing to another. Bill of Material Starts the Bill of Material (tibom1110m000) session in which you can define a bill of material. Task Relationships Starts the Task Relationships (tirou0104m000) session in which you can view and maintain task relationships. Task Relationship - Tools Starts the Task Relationship - Tools (tirou0115m000) session in which you can view and maintain task relationship tools. Operation Steps Use this command to link operation steps to the routing operation in the Operation Steps (tirou1105m000) session. Exceptions Starts the Exceptions (tcuef0105m000) session in which you can define an exception for a specific routing operation. Process Variables Use this command to link process variables directly to the routing operation in the Operation (Step) - Process Variables (tirou1111m000) session. Tools Use this command to link tools directly to the routing operation in the Operation/Operation Step - Tools (tirou1110m000) session. Setup Classes / States Starts the Setup Classes and States by Routing Operation (tirou1104m000) session. Instructions Use this command to link instructions directly to the routing operation in the Operation (Step) - Instructions (tirou1112m000) session. View All Operations Displays all operations. View Effective Oprs Only displays the operations that are effective. Validate Sequence Validates the values of the Next Operation field. Validate Subcontracting Settings of Routing Operations Starts the Validate Subcontracting Settings of Routing Operations (tirou1215m000) session. Phantom Routing Relationships Starts the Phantom Routing Relationships (tirou1103m000) session. Remove Queue, Wait and Move Times Starts the Remove Queue, Wait and Move Times (tirou1220m000) session. Calculate Rate Calculating bottleneck work center and rate Update Lead Time... Click to start the Update Order Lead Times (tirou1202m000) session. The value of the Order Lead Time field is updated. |