9/16/22, 1:01 PM Document 1174520.
1
Copyright (c) 2022, Oracle. All rights reserved. Oracle Confidential.
E1: 31: WO Header Start Date Does Not Match Routing Start Date First Operation
(P48013/P3112) (Doc ID 1174520.1)
In this Document
Purpose
Troubleshooting Steps
Overview
Clarification
Test Case
Test 1 - Standard process
Workaround
Summary
Test 2 - Modified Setup
Detailed Example
References
Related Knowledge Content
References
APPLIES TO:
JD Edwards EnterpriseOne Shop Floor Control - Version XE and later
JD Edwards EnterpriseOne Product Data Management - Version 9.1 and later
JD Edwards EnterpriseOne Requirements Planning - Version XE and later
Information in this document applies to any platform.
PURPOSE
The purpose of this document is to explain why the work order (WO) Start Date on the WO Header (P48013) does not match
the routing's first operation sequence Start Date (P3112) for particular scenarios and provide a workaround for bypassing this
situation.
Certain setups can cause the two Start Dates on the WO Header and on the WO Routing, respectively, to be different.
The workaround provided here may not be suitable for all situations and may not be easily implemented
due to detailed required changes.
TROUBLESHOOTING STEPS
Overview
In a few situations with a particular setup, the start date for a work order may not match the start date of the first operation
sequence in the routing.
The specific setup includes:
Variable Leadtime is defined for a standard manufactured item and the total number of Hours Per Day in the Work
Center Revision (P3006) application differs from the Hours Per Day in the Manufacturing Constants (P3009).
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In addition, Queue and / or Move Hours are defined at the work center (WC) level and / or outside operation step(s)
also involve(s) a large amount of Queue/Move Hours.
For a Variable Leadtime item, if a Work Center is closed (example: for maintenance) by setting the Resource Units to
zero on a day that is a Work Day in that Branch (per the Shop Floor Calendar), the Start Date of the first operation will
be earlier than the WO header Start Date.
Given this scenario, the system may not match the work order Start Date on the Manufacturing Work Order Processing
(P48013) with the Start Date of the first operation sequence on the work order routing (P3112).
Tip: Review work center setup, as changes made there must be followed up with running Refresh Resource Units. See E1:
30/31: How to Setup Resource Units and Run Resource Calendar Refresh (R3007G/P3007) Document 630527.1.
Clarification
This is a known issue due to some limitations of the current code. The system works as designed.
The difference between the work order Start Date and Start Date of the first operation step on the routing exists because the
system does not calculate the work order Start Date on the work order header and the Start Date of the routing's first step
simultaneously. The work order header is created before the work order routing is created. When the routing is created, the
system is not aware of which parts lists and / or other routings will be attached.
Before the work order header is created, the Leadtime Rollup (R30822A) program should be run to calculate the following
values for the parent item. The LTCV value is visible in the Item Branch Table (F4102) only and the LTPU, QUED and SETL
values can be also accessed via P41026 - Addl Sys Info option.
Leadtime Conversion factor (LTCV).
Leadtime Per Unit (LTPU).
Queue Hours (QUED) = the sum of all Queue and Move Hours defined at the work center level (Work Center Master
File - F30006) for all operation sequences on the routing and
Setup Hours (SETL) = the sum of all Setup Hours defined on the routing (P3003) for all operation steps on the routing
(Routing Master File - F3003) .
Whenever the setup on the BOM (P3002) and Routing (P3003) of a parent item are changed, the program Leadtime Rollup
(R30822A) needs to be re-run in order to take into consideration the latest changes and update the values on the Item
Branch file (F4102).
For back scheduling the work order Start Date during work order header creation via Manufacturing Work Order Processing
(P48013) program, the system checks the values previously determined for the parent item by the Leadtime Rollup (written in
the Item Branch Table (F4102)), the total number of Working Hours from Manufacturing Constants (P3009) and the Workday
Calendar table (F0007) for identifying the working days in order to calculate the sum of Leadtime Time per days, Queue Time
in days and Setup Time in days.
The processing option # 3. Back Scheduling Queue and Move Hours on the Defaults tab behind Manufacturing Work Order
Processing (P48013) program, controls how the Leadtime in Days is determined based on the following formula:
If Queue / Move Flag = 1 (The system back schedules queue hours as a percentage of the work hours per day (F3009)
Then:
Leadtime in Hours = Queue Hours + Standard Setup Hours/ Total Work Hours per Day (adding up the 3 shifts)
Leadtime in Days = Leadtime in Hours + Leadtime in Days
Else (Queue / Move Flag = Blank (The system backs chedules queue hours as a percentage of the resource units per
day)
The system determines an 'internal' conversion:
Conversion = Leadtime per Unit (F4102)/LTCV
QueueMove Days = Queue Hours/Conversion
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Leadtime in Days = (Std Setup/Total Work Hours per Day) + QueueMove Days + Leadtime in Days
This is an example of the formula.
While the work order Start Date calculation is happening with a conversion factor, the Routing Date calculation is not using any
conversion factor.
Test Case
The following screen shots were captured to show the differences between a standard process and a modified setup that could
act as a workaround for bypassing this mismatch.
Test 1 - Standard process
1. P3009 - Check the Manufacturing Constants for the number of shifts defined and the working hours defined per
shift:
8 hours / shift x 3 shift / day indicate a total of 24 Work Hours Per Day.
2. P4101 / P41026 - Set up a parent (e.g. with Variable Leadtime) and a component item (e.g. with a Fixed Leadtime).
Populate the necessary fields, as per manufacturing process requirements:
Parent item
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Component item
3. P3006 - Set the work centers as per manufacturing process requirements:
WC 200-201A
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WC Type = 0; Pay Point Code = L; Prime Load = B; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
1 shift of 8.25 working hours / day
Queue Hours = 16 hours; Move Hours = 8 hours; Efficiency = 88%; Utilization = 100%.
WC 200-202A
WC Type = 0; Pay Point Code = L; Prime Load = B; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
3 shifts of 8 working hours / day;
Queue Hours = 80 hours; Move Hours = 8 hours; Efficiency = 88%; Utilization = 100%.
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WC 200-203A
WC Type = 0; Pay Point Code = L; Prime Load = B; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
1 shift of 8.25 working hours / day;
Queue Hours = 16 hours; Move Hours = 8 hours; Efficiency = 100%; Utilization = 100%.
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4. R3007G - Run the UBE to (re)generate the Resource Units available.
5. P3002 - Create the BOM for the parent item:
A single purchased component shall be used for simplifying the test
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6. P3003 - Define the route for the parent item:
Only the first two operation sequences would have Labor and Setup Hours defined but all work centers will have Queue and
Move Hours defined.
7. R30822A - Run the UBE to allow the system to calculate for the parent item the values for the Leadtime Level,
Leadtime Manufacturing, Leadtime Cumulative, Leadtime Per Unit, Setup Hours and Move/Queue Hours field as well as
for [Link].
8. P41026 - Addl Sys Info
Check for the previously mentioned values:
9. P48013 - Create a WO for the parent item with a required quantity of 1 unit:
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Requested Date = 29th of October
Planned Effective Date = 29th of October
WO Start Date = 21st of October
10. R31410 - Run the UBE to process the WO.
11. P3111 - Check the Requested Date of the component on the Work Order Parts List:
Requested Date = 21st of October, as expected.
12. P3112 - Check the Start Date of the first operation sequence of the routing on the Work Order Routing:
Start Date = 18th of October
Workaround
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Any work center previously defined having Queue and / or Move Hours used for any operation step that also involves Labor,
Machine and / or Setup Hours and for which the total Hours Per Day is different from the total Work Hours Per Day in the
Manufacturing Constants (P3009) needs to be split into two different work centers (WC) such as:
Labor, Machine and/or Setup Hours to be reported on an individual work center that could have a different number of
shifts / day and a total number of hours per day than the ones defined on Manufacturing Constants.
While the Queue/Move Hours should be reported on a dummy work center carrying the same number of shifts / day
and working hours per day as the number of working Hours Per Day defined in Manufacturing Constants.
The dummy work center should contain the sum of Queue and Move Hours previously defined. This value should populate
only the Move Hours field on Hours & Efficiency tab in Work Center Master Revision (P3006) program.
Summary
In the Manufacturing Constants program (P3009) there are 3 shifts / day defined, each shift of 8 working hours, indicating a
total of 24 Work Hours Per Day.
Original setup of the Work Center '200-202A':
Work Center Type = 0; Pay Point Code = L; Prime Load = B; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
1 shift of 8 working hours/day
Queue Hours = 16 hours; Move Hours = 8 hours; Utilization = 88%
After revision, work center 200-202A will have the same set up, except Queue Hours = Move Hours = 0 hours.
A new (dummy) work center 'AB' needs to be created, taking into consideration Queue Hours and Move Hours only:
Work Center Type = 0; Pay Point Code = 0; Prime Load = L; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
3 shifts of 8 working hours / day
Queue Hours = 0 hours; Move Hours = 16 (QH - previously defined on work center '200-202A') + 8 (MH - previously defined
on WC '200-202A') = 24 hours;
Efficiency; Utilization = 100%.
To determine the correct Start Date of the first operation sequence on the routing, the Queue and Move Hours defined on
the dummy work centers should be adjusted to match the same number of working days as on the 'standard' setup.
Example
If a work center currently has 40 Queue hours, with only one shift of 8 hours, it means 5 working days are taken into
consideration for the back scheduling process.
If, for a certain operation, it is necessary to wait 5 working days, the dummy work center should have 3 shifts of 8 working
hours each (24 working hours) x 5 days, meaning a total of 120 Queue Hours defined.
The workaround is setup-intensive and therefore time-consuming. It may not always be possible to match
the work order header Start Date with the Start Date of the routing's first operation, but the difference
between the two dates will be significantly decreased.
Test 2 - Modified Setup
1. P3009 - Check the Manufacturing Constants for the number of shifts defined and the working hours defined
per shift:
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8 hours / shift x 3 shift / day indicate a total of 24 Work Hours Per Day.
2. P4101 / P41026 - Set up a parent (with Variable Leadtime) and a component item (with a Fixed Leadtime). Populate
the necessary fields, as per manufacturing process requirements:
Parent item
Component item
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3. P3006 - Define the new work centers and modify the previous work centers by removing the Queue and Move Hours
values:
Set the work centers as per manufacturing process requirements and split the 'standard' work centers into 2 different work
centers, as follows:
Remove any Queue and/or Move Hours from the work centers used on the five routing steps.
Create individual dummy work centers for corresponding Queue Hours and Move Hours removed from the original work
centers and define the same number of Working Hours / day as the Work Hours Per Day defined on P3009.
Detailed Example
Work center 'A' (as per the original setup, except no Queue and / or Move Hours defined).
A new (dummy) Work Center'AB' should be created, taking into consideration Queue Hours and Move Hours only:
Number of shifts and number of working hours / day as per Manufacturing Constants setup;
Queue Hours = 0 hours; Move Hours = X (QH previously defined on the work center 'A') + Y (MH previously defined on the
WC 'A') = Z hours.
WC 200-201A
WC Type = 0; Pay Point Code = L; Prime Load = B; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
1 shift of 8.25 working hours / day
Queue Hours = 0 hours; Move Hours = 0 hours; Efficiency = 88%; Utilization = 100%.
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New WC 200-201AA
WC Type = 0; Pay Point Code = 0; Prime Load = L; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
3 shifts of 8 working hours / day (as per Mfg Constants setup)
Queue Hours = 0 hours; Move Hours = 24 hours (16 + 8) ; Efficiency & Utilization = 100%.
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WC 200-202A
WC Type = 0; Pay Point Code = L; Prime Load = B; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
3 shifts of 8 working hours / day
Queue Hours = 0 hours; Move Hours = 0 hours; Efficiency = 88%; Utilization = 100%.
New WC 200-202AA
WC Type = 0; Pay Point Code = 0; Prime Load = L; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
3 shifts of 8 working hours / day (as per Mfg Constants setup)
Queue Hours = 0 hours; Move Hours = 88 hours (80 + 8) ; Efficiency & Utilization = 100%.
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WC 200-203A:
WC Type = 0; Pay Point Code = L; Prime Load = B; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
1 shift of 8.25 working hours / day
Queue Hours = 0 hours; Move Hours = 0 hours; Efficiency & Utilization = 100%.
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New WC 200-203AA:
WC Type = 0; Pay Point Code = 0; Prime Load = L; Critical W/C = 3;
Crew Size; Number of Machines & Number of Employees = 1;
3 shifts of 8 working hours / day (as per Mfg Constants setup)
Queue Hours = 0 hours; Move Hours = 24 hours (16 + 8) ; Efficiency & Utilization = 100%.
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4. R3007G - Run the UBE to regenerate the resource units
5. P3002 - Create the BOM for the parent item (as per Test 1 - Standard process)
6. P3003 - Define the routing for the parent item, such as adding the newly defined work centers
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7. R30822A - Run the UBE to allow the system to calculate the values for the Leadtime Level, Leadtime Manufacturing,
Leadtime Cumulative, Leadtime Per Unit, Setup Hours and Move/Queue Hours field as well as for [Link] of the
parent item.
The processing options for R30822A:
P.O. # 3. 'Calculate Leadtime Level for Queue and Move Hours' = Blank = The system uses queue hours as a
percentage of the Work Center shift hours per day (F30006).
P.O. # 4. 'Zero Move/Queue hours in Routings' = Blank = Use Move Hours and Queue Hours from the Standard Routing
(P3003) to calculate item's leadtime values.
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8. P41026 - Addl Sys Info
Check the values for the parent item determined by the system: Leadtime Level, Leadtime Manufacturing, Leadtime
Cumulative, Leadtime Per Unit, Setup Hours and Move/Queue Hours field as well as [Link].
9. P48013 - Create a work order for the parent item with a required quantity of 1 unit:
The processing options for P48013:
P.O. # 3. 'Back Scheduling Queue and Move Hours' = 1 = The system back schedules queue hours as a percentage of
the work hours per day.
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Requested Date = 29th of October
Planned Effective Date = 29th of October
WO Start Date = 21st of October
10. R31410 - Run the UBE to process the WO
The processing options for R31410, '5 - Routing' tab:
P.O. # 8. 'Back Scheduling Queue and Move Hours' = Blank = The system back schedules queue hours as a percentage
of the resource units per day.
P.O. # 9. 'Queue and Move Hours' = Blank = If queue hours and move hours are blank or zero in the standard routing,
do not enter queue hours and move hours from the work center into the work order routing.
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11. P3111 - Check the Requested Date of the component:
Requested Date = 21st of October, as expected.
12. P3112 - Check the Start Date of the first operation sequence of the routing:
Start Date = 20th of October
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Extensive testing has proven that when the standard work centers have a large number or Queue and / or Move hours and /
or an outside operation step is also involved into the process, the gap between the work order Start Date and Start Date of the
routing's first operation sequence can be significant, creating related problems with other modules from the Planning side
(MRP, CRP).
By applying the above workaround, the gap between the two dates would be decreased to one working day or even
canceled.
References
The following enhancement BUGs request to modify the existing functionality to match the work order Start Date with
routing's Start Date (first operation sequence on the routing):
BUG 10962752 - 'First Operation Date and the WO',
BUG 11029741 - 'OP START < WO START W/VAR LT',
BUG 11039357 - 'Parts List Start Date' and
BUG 10939419 - Start Date On First Operation'.
Related Knowledge Content
For detailed information on Leadtime Level, Leadtime Rollup, Work Order Header details and how the WO Start Date is back
scheduled, check the following:
E1: 30: R30822A Understanding Leadtime Rollup - Document 1381378.1
E1: 31: How Work Order Start Date is Calculated for Variable Lead Time - Document 881632.1
E1: 31: P48013 Work Order Header Definition and Use - Document 633410.1
E1: 31: P48013 Work Order Header FAQ - Document 631351.1
E1: 31: Work Order Start Dates & Back Scheduling Calculations (P48013 & P3112) - Document 626117.1
E1: 31: Mfg Work Orders & Routing Instructions Back Scheduling FAQ - Document 646079.1
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discussion in the E1 Manufacturing Community.
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