444 QAD Web UI Quick Start Training Guide
CHAPTER 16
Manufacturing Setup One
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Overview
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Manufacturing Setup Process Flow One
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Product Structures
A product structure is a bill of material that lists all the subassemblies, intermediates, parts, and raw materials
that go into the parent assembly, including the quantity of each that is required. It guides product
manufacturing.
The role we are using here is a Mfg Engineering Mgr. You can access Product Structures from the Product
Definition menu.
Product structures are based on item numbers or product structure codes. You can create a new product
structure in two ways:
• Using an existing item number
• Assigning a new product structure code
In the Product Structures Main panel, you can enter the product structure code and description.
If the product structure code is an existing item number, the UM and Description fields default, based on the
item number.
Optionally, if you select the Formula field, then you are defining a formula. The Batch Size field displays.
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Product Structures
If the product structure code is not an existing item number, you are defining a pure BOM code and you can
enter a new product structure code, including the Description and UM fields.
Select Formula to define a formula. The Batch Size field displays.
Select Service BOM to define a service product structure (associated with SSM).
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Product Structures
In the Components panel, click New to add a component for the product structure.
The first field in the grid is the Type field, which defaults to Item. The type field toggles the lookup in the
Component field between the item master table and the BOM master table. In the Component field, select
item using the lookup (item master table), or manually enter an existing item number.
You can also add a BOM code as a component of a product structure by changing the Type field to BOM (this
changes the lookup to BOM master table) or manually entering the BOM code in the Component field.
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Product Structures
Select a component and click the Details icon to update fields value in the Parent-Component Relationship
panel.
Enter Quantity Per to specify how much of this component is needed to make the parent item. In discrete
manufacturing, items are made in individual units, and the component quantity is the amount needed for a
single unit of a parent product. For example, two screws are required for one pair of sunglass frames.
In process manufacturing, products are made in batches and the component quantity per parent on a formula
or recipe is stated with respect to a batch quantity for the parent product. Since the only economical way to
coat lenses is in batches, the amount of a particular coating might be specified for a batch of several hundred
lenses.
Enter the Operation number identifying the operation in the routing or process where this component is used.
Optionally, enter a product type code. Product structure relationships normally have a blank structure type
code. Other codes are used for special applications.
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Product Structures
Each component has a read-only Level field. A component with Levels selected has its own product structure.
When Levels is not selected, the component does not have a subordinate product structure.
On a component where Levels is unchecked, you can still directly create a structure for that component by
clicking the Open Structure button.
When you click the Open Structure button, a message prompts you to create a new structure. If you click Yes
to begin the process of creating a new structure, just as if you had clicked New above the Summary panel.
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Product Structures
A component with Levels selected has its own product structure. When a component of a product structure is
itself a parent item, you can add or update child-level components.
You can easily determine such relationships using the Levels field on the component grid or details form.
When Levels is checked, the item can have a subordinate structure.
If you have added an existing BOM code to the product structure, the Levels field will be checked to show
that it is indeed a structure.
On a component where Levels is selected, you can click Open Structure to view the subcomponent structure
of the selected component.
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Product Structures
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Product Structures
Use the Alternatives panel to see alternate product structures that can be used to produce the parent item.
When the product structure is not a pure BOM (that is, the product structure code is an item number), an
additional grid panel below the Components grid displays a list of all the alternate structures that can be used
to produce the item.
Alternatives can come from any of the following sources:
• Structures set up in Alternate Structure Maintenance in .NET UI . The Source field in this case is Alternate.
• BOM/Formula field populated in Item-Site Planning Maintenance. The source field in this case is Item-Site.
• BOM/Formula field populated in Item Master Maintenance. The Source field in this case is Item
BOM/Formula. The Site field will also show the specific site where the setup has been made.
• The item itself in Item Master. The BOM/Formula field is non-blank. The item number with BOM/Formula
= item number should appear in the grid. The Source field in this case is Item.
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Product Structures
Product Structures includes the ability to set up configured items. You can use Product Structures to define
structures for configured items.
The P/M column in the main Product Structures browse identifies items defined with a purchase manufacture
code of C (Configured) in Item Master Maintenance.
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Product Structures
When you select a product structure record for a configured item, you can add, edit, or delete the configured
product options in the Options grid.
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Product Structures
Use the Where Used grid to view product structures and formulas that use the item.
The Web UI includes where-used functionality, which is only available in .NET UI as a separate report or
inquiry. You can either click the Where Used tab or scroll down to view where the current record is used.
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Product Structure by Item Report
Use Product Structure by Item Report to view product structure information.
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Departments
Use Departments to manage the department code for manufacturing a product.
Departments group work centers for capacity requirements planning and general ledger (GL). Similar to
product lines, departments are used to determine the GL accounts on transactions and for summary capacity
planning.
At least one department is required before entering work centers or routings. Every work center must belong
to one department.
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Work Centers
Use Work Centers to manage the work center code for manufacturing a product.
A work center is a production facility that performs specified tasks. Departments are a prerequisite to entering
work centers.
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Routings
Use Routings to manage the operations for manufacturing a product.
To manufacture an item or product, you must complete one or more activities or operations. The list of
required operations is called a routing, which basically defines the process needed to produce the item or
product.
If a product structure is the list of ingredients in a recipe, a routing is the directions. The routing is generally
associated with some elements such as work centers, machines, sequence of operations, and required tools.
A routing also provides manufacturing instructions such as how long it takes to produce items, what quantities
are produced and by whom, whether there are any interruptions to production, and so on.
In addition, a routing contains data used as a standard for evaluating production, operation times, yield
percentages, the number of machines normally needed, and so on. The work center codes associated with
routing operations link actual production results with capacity planning, cost accounting, and other programs.
Routings can be used in various scenarios such as:
• Calculating the cost of producing an item.
• Calculating the time it takes to manufacture an item.
• Scheduling operations for production orders and repetitive schedules.
• Calculating load in work centers.
• Printing routings for production orders.
The Routings view allows you to create, modify, or delete routings. To open the Routings view, you can either
choose Product Definition > Routings or enter Routings in the Search field.
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As in other QAD Web UI functions, the Routings menu is associated with roles; in this case, Master
Scheduler, Mfg Engineering Manager, Production Manager, Production Operator, and Quality Manager.
When you are assigned one of those roles, you can find Routings under the Product Definition menu.
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Routings
The Operations panel allows you to click New to create more operations for the routing, or to select an
existing operation record and click Edit or Delete to modify or remove it.
You can also click Details on this panel to open the Routing Operations hybrid view. You can then set
attributes and options for the operations involved in the routing, including the operation number, operation
time, operation options, subcontract details, and costing data.
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Routings
After you set up a routing, you can link it to an item in several ways, depending on whether this routing
should be used as the default routing code or available for use as an alternate routing.
The Item Routing Assignment panel enables you to specify for which item the selected routing can be used.
You can click New to define more items. The Edit, Delete, and Details buttons are enabled only after you
select an item whose Source is Alternate on this panel. This then enables you to modify or delete such an item,
or to launch the Alternate Routings hybrid view for further maintenance.
You can also define an alternate routing for an item site in Items.
After you add an item on this panel for a routing (for example, routing A), you can set Routing of this item to
routing A when creating a production order for manufacturing this item.
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Production Lines
A production line is defined at a site by specifying the hourly production rate for items produced on that line
during a normal shift. One or more items can be made on the same production line, and the same item can be
produced on several production lines, all at the same or at different production rates. Optionally, orders for an
item can be allocated to several different production lines.
The role we are using here is a Mfg Engineering Mgr. You can access the Production Lines from the Product
Definition menu.
Select a site and enter production line code, description, and units/hour.
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Production Lines
On the Line Items panel, you specify attributes and options for specific items that you manufacture on the
production line.
Enter the item being manufactured, either a finished product or an intermediate product or subassembly. The
item can be a co-product/by-product or base process item.
The item number, site, and production line together determine the default routing code, BOM code, estimated
yield, lead time calculation, and components for the order from data setup for the item, item-site, and item and
production line.
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Review
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Exercise: Manufacturing Setup One
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Exercise: Manufacturing Setup One
In this exercise, you will set up items, product structure, routing, production line, and costing roll-up in Web
UI.
1. Log in to Web UI as demo@[Link] user. Use Items to create three items:
Item 90001
Description Airbag
Product Line 10
Item Status Active
Site 10-100
Location 010
Purchase/Manufacture L
Item 91001
Description Cushion
Product Line 20
Item Status Active
Site 10-100
Location 020
GL Cost - Material 10
Item 91002
Description Inflator
Product Line 20
Item Status Active
Site 10-100
Location 020
GL Cost - Material 10
2. Use Product Structures & Formulas to create a new product structure 90001. The parent is item 90001 and
the components are 91001 and 91002. Each component’s quantity per is 1 and is in the operation 10.
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3. Use Routings to create a new routing 90001. Add one operation 10 on work center 1000; the run time is 1
hour for each product.
4. Use Production Lines to create a new production line PL90001; planning units per hour is 100. Add line
item 90001 for the production line with the same planning units per hour.
5. Use Routing Cost Roll-Up to roll up the routing cost for the product 90001 on site 10-100. Use Product
Structure Cost Roll-Up to roll up the product structure cost for the product 90001 on site 10-100.
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