Manufacturing Standards - Initial Exercises

Initial Exercises

Purpose: The purpose of these initial exercises is that the instructor will use them for demonstrating the basic functionality in Manufacturing Standard, which entails:

• Performing Engineering Transfer

• Creating Product Structure

• Creating Recipe Structure

• Creating Plan Structure

• Creating Routing

• Calculate Lead time

• Creating New Structure/Routing Revision

• Creating New Part Revision

• Creating Structure/Routing Alternative

Performing Engineering Transfer

Purpose: The purpose of this exercise is to familiarize you with the basic functionality of transferring parts and structures from IFS Engineering.

Prerequisites: Manufactured and purchase engineering parts must exist.

Windows:
Engineering Revision Transfers
Product Structure

Note: Engineering parts are site independent. 

1. Open the Engineering Revision Transfers window. Make sure that your site appears in the header. If not, switch to your site.
2. Query (F3) for Part 20–100 Engine and Eng Revision R02.
3. Look at the information in the Action Planner, Action Mfg Engineer, Part Type, and Part Template ID columns. 

Note: Once templates are created in the Part Transfer Template window, they are automatically connected to the correct part type, and the information appears in the columns listed above. 

4. Select the row for part 20-100 Engine and Eng Rev R02, right-click, and click Direct Transfer.
5. Select the Single Level Transfer and Execute Transfer Online check boxes. If these check boxes are not checked, the job will run in the background.
6. Open the Product Structure window, and verify that the part and first structure level have been transferred. 
7. Query (F3) for Part 20–100. Make sure that the components listed in the table below are included.

Creating Product Structure

Purpose: The purpose of this exercise is to introduce you to the basic functionality for creating a product structure. 

Prerequisites: Manufactured and purchased inventory parts must exist.

Note: If you have not yet already done so, copy Inventory Part 20–250 on Site 1 to IE20–250, also on Site 1.

Windows:
Product Structure

1. Open the Product Structure window.
2. Query (F3) for Part IE20–250 on Site 1.
3. Click the Product Structure tab.
4. Select structure alternative * (asterisk).
5. Create a new line (F5) for each part, and enter the structure shown in the table below.

   Line Item No	Component Part	Qty per Assembly
   1	20–350	1
   2	20–351	1
   3	20–352	1

6. Save your changes (F12).
7. Right-click and then click Buildable to set the structure to buildable.
8. Component Part 20–351 is a manufactured part, so you can see the multilevel structure in the Product structure/Query-Multi Level tab.
9. Optionally, select Line 2, right-click, and then click Next Level to see the components for Part 20–351.
10. The structure is now ready, and you can create the shop order for Part IE20–250. 

Creating Recipe Structure

Purpose: The purpose of this exercise is to introduce you to the basic functionality for creating a recipe structure

Prerequisites: Manufactured recipe and purchased inventory parts

Note: If you have not yet already done so, copy Inventory Part 80–400 on Site 1 to IE80–400, also on Site 1.

Windows:
Recipe Structure

1. Open the Recipe Structure window.
2. Query (F3) for Part IE80–400 on Site 1.
3. Click the Recipe Structure tab.
4. Select structure alternative * (asterisk).
5. Create a new line (F5) for each component part, and enter the structure shown in the table below.
   

   Line Item No	Component Part	Qty in Display Weight
   1	80–501	76.0
   2	80–502	64.0
   3	80–505	44.0
   4	80–510	16.0
   5	80–506	–0.2

6. Save your changes (F12).
7. Right-click and then click Buildable to set the structure to buildable.
8. Component Part 80–400 is a manufactured recipe part, so you can see the multilevel structure on the Recipe Structure/Query – Multi Level  tab. 
9. The structure is now ready, and you can create the shop order for Part IE80–400. 

Creating Plan Structure

Purpose: The purpose of this exercise is to introduce you to the basic functionality for creating a planning structure.

Prerequisites: Manufactured and purchase inventory parts must exist.

Note: If you have not yet already done so, copy Inventory Part 20–000 on Site 1 to IE20–000, also on Site 1.

Windows:
Planning Structure

1. Open the Planning Structure window.
2. Query (F3) for Part IE20–200 on Site 1.
3. Click the Planning Structure tab.
4. Create a new line (F5), and enter the structure shown in the table below.

   Line Item No	Component Part	Qty per Assembly (Percentage)
   1	20–101	0.4
   2	20–102	0.7

4. Save your changes (F12).
5. Right-click and then click Plan to set the structure to Plannable.

Creating Routing

Purpose: The purpose of this exercise is to introduce you to the basic functionality for creating routing and to enter some of the data for an operation.

Prerequisites: A structure must exist for the part.

Windows:
Routing

1. Open the Routing window.
2. Query (F3) for Part IE20–250 on Site 1.
3. Click the Routings tab, and create a new line (F5).
4. Enter the operation using the information shown in the table below.

   Operation No.	Description	Work Center	Machine Setup time	Machine Run Factor	Labor Class	Labor Setup Time	Labor Run Factor	Factor Unit
   10	Assemble Part	300	0	0.2	1	0	0.2	Hours/Unit

5. Save your changes (F12).
6. The labor setup time and labor run time are optional values. If you want to use either of them, keep in mind that you must enter the labor class. 
7. Right-click and then click Buildable to set the structure to buildable. The routing is now ready to be used in a shop order.

Calculate Manufacturing Lead time

Purpose: The purpose of this exercise is to familiarize you with the basic functionality for calculating the manufacturing and cumulative lead time.

Prerequisites: A structure must exist with a routing connected as described above.

Windows:
Lead time Calculation
Cumulative Lead time Calculation
Inventory Part

Note: IFS Racing has entered its manufactured parts with their structures and routings. Your next objective is to update the calculated lead time for the parts.

1. Open the Lead time Calculation window.
2. In the Site field, select site 1 from the List of Values.
3. In the Part No field, enter IE20-250. If you leave this field blank, all parts for Site 1 will be calculated.
4. Under Capacity, select the Average check box to base the calculation on the average capacity of the work centers.
5. Under No Routing Option, select the Leave Unmodified check box. This option does not update the lead time on parts for which the routing is missing.
6. Under Leadtime Calculation Basis, select Machine Time Only to base the calculation on machine time. The calculation will not consider labor time.
7. Click OK.

Note: The calculate is a batch job, so you must wait for the job to run.

8. Open the Inventory Part window, and click the Acquisition tab.
9. Query (F3) for Part Number IE20–250. Note the manufacturing lead time.
10. Click the Manufacturing tab. Note the fixed and the variable lead times.
11. Click the Acquisition tab again. Add the purchase lead time for parts as shown in the table below.

12. Open the Cumulative Lead time Calculation window.
13. In the Site field, select Site 1 from the List of Values.
14. In Part No field, enter lE20–250. If you leave this field blank, you will calculate all parts for Site 1.
15. Click OK.

Note: The calculate is a batch job, so you must wait for the job to run.

16. Open the Inventory Part window, and click the Manufacturing tab.
17. Query (F3) for Part Number IE20–250. Note how the cumulative lead time compares to the manufacturing lead time.

Creating New Structure/Routing Revision

Purpose: The purpose of this exercise is to familiarize you with the basic functionality for creating new revisions.

Prerequisites: A structure with a routing connected must exist.

Windows:
Product Structure
Routing

1. Open the Product Structure window.
2. Query (F3) for Part Number IE20–250.
3. Right-click and then click Copy Structure Revision.
4. Enter Destination Revision 2, and enter a date 15 days after today as the phase-in date. The new revision appears.

Note: The same procedure applies to routings.

Creating New Part Revision

Purpose: The purpose of this exercise is to familiarize you with the basic functionality for part revisions.

Prerequisites: An inventory part must exist.

Windows:
Part Revision
Part Revisions

1. Open the Part Revisions window.
2. Query (F3) for Part Number IE20–250.
3. You can create a new revision by clicking either New (F5) or Copy (F6). 
4. Enter information according to the table below. Be sure to leave the Revision No. field blank. This value is generated automatically.
5. Save your changes (F12).

Creating New Structure/Routing Alternative

Purpose: The purpose of this exercise is to familiarize you with the basic functionality for creating new alternatives.

Prerequisites: A structure/routing and a purchase part must exist. 

Windows:
Product Structure
Routing

1. Open the Product Structure window.
2. Query (F3) for Part Number IE20–250.
3. Click the Product Structure tab.
4. In the Alternative field, create a new alternative by clicking either New (F5) or Copy (F6). 
5. Enter the information shown in the table below. 

6. Save your changes (F12).

Note: The same procedure applies to recipe structure and routings.

7. Create a new line (F5) for each component part, and enter the structure shown in the table below.