Overview of Design Project Delivery Product Data—Exercises

Basic Data Setup

Site 

Purpose: The purpose of this exercise is to show you how to create a site and connect it to your user ID.

Windows:
Site
Sites per User

1. Create your own site, substituting your initials for XX, as shown in the following table:

2. Connect your site to your chosen user ID.
3. Save your changes. 

General exercises for Entering Site

Main Exercises

Purpose: The purpose of this exercise is to do copy the standard planned engine parts from the engineering transfer site (1) to your site, enter inventory planning data, enter estimated material costs, copy part structures, work centers and routings and calculate costing for these parts.These standard planned parts are used in the design of the project product structure. 

Windows:
Copy Parts to Site
Background Jobs
Inventory Part/Planning Data
Inventory Parts
Product Structure
Manufacturing Standard Basic Data/Work Center Department
Work Center
Work Center/Cost
Manufacturing Labor Class
Manufacturing Labor Class/Cost Routing
Routing/Routings
Part Cost
All Levels Part Cost Calculation
Part Cost/Cost Build–up Tree View
Copy Costs to Cost Set One
Inventory Part
Inventory Part/Costs

Copying Inventory Parts

Prerequisite: You must connect both your own site and site 1 to your chosen user ID. 

1. Open the Copy Parts to Site window.
2. Copy all parts from site 1 to your site using 270 as the value for Comm. Group 2.
3. Click OK. Note that this is a background job.
4. Open the Background Jobs window, and verify that the background job completed without error.

Note: If you already have the simple racing engine parts in your site, use your existing parts. These parts all have part numbers beginning with the prefix 20, followed by a dash and three digits, e.g., 20–100.

Entering Inventory Part Planning Data

1. Open the Inventory Part window and query for your site.

2. Click the Planning Data tab.

3. For each of the parts listed in the table below, i.e., the parts you copied from the previous exercise, enter the specified value for the planning method.

Note: If you already have the same planning data, i.e., the planning method for the racing engine parts in your site, use your existing parts.

4. Save your changes.

Entering Inventory Part Estimated Material Cost

1. Open the Inventory Parts window and query for your site.

2. For each of the parts listed in the table below, enter the specified values for Estimated Material Cost.

Note: If you already have the material costs for the racing engine parts in your site, use your existing parts. The parts 20–100 (Engine 1600) and 20–120 (Cylinder Head 1600) are not in the table because they are both manufactured parts, of which costing for them will be calculated later in the exercises. 

3. Save your changes.

Note: You can query for your site with the lead time code of Purchased and part numbers that match the search string 20–%. Moving the Estimated Material Cost column close to the Part No. column will make it easier to keep track of your place in the list.

Copying Part Revision and Product Structure

Note: The destination revision number will be changed automatically to the next higher integer from the source revision number.  Therefore, you must change the site to your site first then the revision number to match the source revision number. In addition, the structure type will default to a value other than Manufacturing if another value exists. Make sure that the structure type is Manufacturing. However, if you already have the product structures for the racing engine parts in your site, use your existing structures. 

1. Open the Product Structure window and query for site 1.
2. In the Part No list, click part 20–120.
3. On the header portion, right-click and then click Copy Structure Revision to copy the manufacturing structure revision for part 20–120 in the table below from Site 1 for to your site. You can also click List to see the list of sites.

4. Click OK.
5. On the Product Structure window, query for your site and the two parts in the table.
6. In the Product Structure tab, verify that the structure for both parts have been copied.
7. Set the structure alternate to Buildable by going to the State field and right-clicking and then click Build.
8. Repeat steps 2–7 above for the other part 20–100. 

Copying Work Center Departments and Work Centers

1. Open the Manufacturing Standard Basic Data window.

2. Click the Work Center Department tab.

3. Query for site 1.

4. Copy the departments 10, 30 and 80 to your site by clicking Duplicate. Make sure you change the site to your site before saving.

5. Open the Work Center window and query for site 1.

6. In the Work Center list, click work center 100.

7. Copy work center 100 to your site by clicking Duplicate. Make sure you change the site to your site before saving.

Note: If you already have the work centers for the racing engine parts in your site, use your existing work centers.

8. Click the Cost tab, and set costs for the cost sets 1 and 2 to the values shown in the table above.
9. Save your changes.
10. Repeat steps 5–9 for work centers 300 and 810.

Copying Labor Class and Routing Revision

1. Open the Manufacturing Labor Class window.

2. Query for site 1 and labor classes 1, 3 and 6. 

3. Copy each labor class at a time to your site by clicking Duplicate. Make sure you change the site to your site before saving.

4. Click the Cost tab, and set costs for the cost sets 1 and 2 to the values shown in the table below.

5. Save your changes.

6. Open the Routing window and query for site 1.

7. In the Part No list, click part 20–120.

8. On the header portion, right-click and then click Copy Routing Revision to copy the manufacturing routing revision for part 20–120 listed in the table below from site 1 to your site. You can also click List to see the list of sites.

Note: If you already have the routings for the racing engine parts in your site, use your existing routings. Only parts 20–100 and 20–120 are in the table because they both have a product structure.

Note: The destination revision number will automatically be changed to the next higher integer from the source revision number. Therefore, you must change the site to your site first and then change the revision number to match the source revision number. Otherwise, an overlapping date range may result. In addition, the routing type will default to a value other than Manufacturing if another value exists. Verify that the routing type is Manufacturing.

9. Click OK.
10. On the Routing window, query for your site and the two parts in the table.
11. In the Routings tab, verify that the structure for both parts have been copied.
12. Set the routing alternate to Buildable by going to the State field and right-clicking and then click Build.
13. Repeat steps 6–12 above for the other part 20–100. 

Calculating Part Cost

Note: If you already have the racing engine parts in your site, use your existing parts.

1. Open the Part Cost window and query for part 20–120 at your site.
2. Click the Part No list and select Cost Set 2.
3. On the header, right-click and then click Cost Calculations - Calculate Part Costs–All Levels.
4. Verify that the Site is your site, the Part No is 20–120 and the Cost Set is 2.
5. Click OK.
6. Go back to the Part Cost window and refresh it.
7. On the Cost Build–up Tree View tab, verify that costs in Cost Set 2 have been calculated for the part.
8. On the header, right-click and then click Copy Costs to Cost Set One.
9. Verify that the site is your site.
10. Copy the costs From Cost Set 2. You can also click List to see the list of cost sets.
11. Click OK. Note that this is a background job.

Note: If you get messages about zero cost for the discrete racing engine parts, check to see whether any of the possible problems listed at the end of the main exercise is the cause.

12. Open the Background Jobs window, and verify that the background job completed without error. Review the details, and make sure that there are no messages about zero cost not being allowed for the parts.
13. Go back to the Part Cost window, click the Part No list, and select Cost Set 1 for part 20–120.
14. Verify that costs in Cost Set 1 have been copied for the part.
15. Open the Inventory Part window.
16. Query for part 20–120 at your site.
17. Click the Costs tab.
18. Verify that the inventory value is 3338.20.
19. Do the same steps 1–17 for part 20–100.
20. Verify that the inventory value is 7942.60

Note: If the values in the steps above do not match, results in some of the Project Delivery exercises will not match. To correct the values, consider the following possibilities:

• If the inventory value is zero, then the part cost steps were not completed.
• One or more of the estimated material cost values were not set correctly. This would affect cost but not lead time.
• One or more of the product structures were not copied or were not set to Buildable. This would affect both cost and lead time.
• One or more of the routings were not copied or were not set to Buildable. This would affect both cost and lead time.
• One or more of the work center cost values were not set correctly. This would affect cost but not lead time.
• One or more of the labor class cost values were not set correctly. This would affect cost but not lead time.

If you are having trouble finding the source of the discrepancy, compare the part cost of the parts in your site with those in site 1.