You can change your master schedule by specifying the type of master schedule update to perform. You can run a Net Change or Regenerative Schedule.

You also have the ability to clear the lower level requirements out of the Planned and Firm-Planned Order file.

Understanding: What Was Issued to the Shop Order

The shop order inquiry program provides several function keys. By using the function key for the material, the display will present what components have been issued under the issued quantity column. You are also presented with the required quantity. While viewing the quantities you may see that more was issued than what was required. Possibly there was scrap and more material was required to be issued. Perhaps there was an over issue and the balance of the material is slated to be returned to stock.

A red flag should go up if the Shop Order quantity finished is equal to the required quantity for the end item and all the components have not been issued. You may want to investigate why.

Understanding: The quantities required, finished and remaining at the operation and in total for the Shop Order

The shop order may require 1,000 pieces but only 950 are reported as finished in total for the shop order. The quantity required is what is planned on the SO and it may be a higher number than what is finished, factoring in that there can be scrap. If a 1,000 pieces are required to be produced, and there is always is scrap of 10 pieces, then plan for scheduling a quantity of 1,010.

The quantity finished for the end item is what is reported in the inventory application with a production order receipt transaction. At the operation level, if the quantity is reported at the operation, there will be a value in the PCS Complete field on the operation detail screen showing the pieces completed through that operation.

If you want to get a handle on the difference between the required quantity and the finished quantity, you may want to look into reporting quantities at the operation level as well as examining how scrap is controlled and reported.

Understanding: How many hours remain in total and at each operation?

Now let’s look at what information is being supplied from the shop floor.

It’s not uncommon for transaction reporting to be captured manually on the shop packet that was issued to the factory floor when the SO was released.

The big question is, is anything done with the data? Is it collected and keyed to a  spreadsheet and not shared, or is the transaction data keyed to SFC600? If it is being keyed, ask how often and by whom? Some companies use alternative methods to capture transaction data that do not require batch keying via a keyboard.

Not a lot of data is required to be keyed to SFC600 in order for the SO Inquiry to be useful. The data that should be reported for the transaction process is as follows:

• The type of hours being reported – machine, run labor, setup labor
• If reporting setup and run labor you want an employee clock number
• The shop order and the operation that is being reported
• Is the operation complete
• How many good were produced at this operation
• How many hours – the numbers of hours are critical. Do the employees estimate how many hours they worked, or do they track actual time started and stopped in order to calculate the actual number of hours.

Based on what is captured and how often will have an impact on the SO inquiry screen. Understanding the batch times as to when the transactions are keyed will provide you with the window as to the SO status at that point in time. Or, are they keyed as they happen in a near real time fashion so that you can have a more current view of the factory floor.

Understanding: How many hours remain in total and at each operation?

First let’s look at some key BPCS Master File data starting with the routing file.

How many routing steps (operations) are set up that reflect how the product is produced in the factory? If you take a short cut and set up only one operation for the entire process, then you will limit the information seen on the SO inquiry program. Set up the operation steps to reflect what you want to report back to from the factory floor.

Will each of the routing steps run in one work center, or in different work centers? To keep it simple you may want to set up work centers as departments. For example:

• Assembly
• Machine
• Paint
• Etc.

For each operation setup consider how you have set up the following:

• Load Codes – for example a code 5 is used if reporting both setup time and run labor time. These codes are maintained in the work center file
• Basis Code – typical codes are P for pieces per hour,  3 is used for hours per 1,000 pieces
• Setup hours – if you set them up, you also want to report them
• Run hours – Direct Labor
• Machine hours

How you set up th

Came across an article online from Lauber CFO’s, and thought I would share. Here is a checklist for things to consider in order to finish out the year and help you plan for 2016:

• Are your accounting records up to date so that you can make a projection of how the current year will turn out?
• Are all account reconciliations currently up to date to facilitate the closing of the books after year end?
• Are there accounts receivable that should be reserved for or written off prior to the end of the year?
• If your business carries inventory, do you need to plan a physical count as of the end of the year?
• Has depreciation on your fixed assets been recorded during the year? Have you considered depreciation on current year additions?
• Have all new asset purchases and bank loans been recorded on your books?
• Are there any liabilities, for example, pending legal actions or warranty issues, which will need to be recorded prior to year end? 
• Do you have a plan in place to properly “cut-off” revenue at year end to properly match revenue and expense?
• Will there be bonuses, profit sharing contributions or discretionary retirement plan contributions paid prior to the end of the year? How will these payments affect cash f

Some items in the manufacturing process may require a lot number. A quick and easy way to release the Shop Orders with lot numbers is by using the Multi-Level Shop Order Release.

Simply select the end item from the selection screen and use action 10 for the multi-level order release. At the bottom of the release screen is the field “Pre-Assign a Lot Number to Shop Orders”. Select 1 for the pre-assigned lot number assignment option.

This option will use the pre-assigned lot number on the shop order, if the lot number exists. If the lot number does not exist, the system will automatically create a lot number and assign it to the shop order for all items that are lot-controlled.

Just a refresher on a tip I’ve shared previously from supply Chain Technology Bulletin regarding how to attain greater inventory accuracy. I thought it would be worthwhile to share again:

1. Record data regarding your inventory as soon as the items arrive at your door / receiving dock. With information, you can make decisions. Without it, you waste money, time, and effort.
2. Leverage data collection, label generation, and RFID solutions to make your life easier.
3. Set inventory accuracy goals for the business and for employees.
4. Train your employees so they know what is expected of them, and how to best perform their job and therefore how best to maintain accurate inventory counts.
5. Count the inventory – and do it regularly. Find a method that works best for your employees, and for your business.