Initial Exercises—Manufacturing Standards for CTO

Note: The total accumulated cost is partly determined by the usage factor. The usage factor affects MRP in the same manner.

Creating Configuration Conditions

Purpose: The purpose of this exercise is to create the conditions that determine when a component is selected from a configuration structure. 

Prerequisites: A configuration structure (IE–11) must exist, as must a configuration family with connected characteristics (EASYFLEX).

Windows:
Configuration Structure, or
Configuration Structure Graphic

Note: When working with CTO parts, you build a configuration structure consisting of all components needed for every possible configuration, including those components that are optional. To create a structure for production that corresponds to the customer specification, you enter conditions to select the correct parts for each case. The rules (condition/action) will be defined in the same manner regardless of the element to which the rule is attached. You can define rules for the following elements: configuration structure alternative, routing alternative, components, operations, work guidelines, and tools.

1. Open the Configuration Structure window, and query (F3) for the IE–11 part number on site 1.
2. Select the * (asterisk) alternative.
3. Select the component 150 line, because you will add a condition to this component.
4. Right-click and then click Configuration Structure Rules.
5. Review the part information. On the tabs, you can see the characteristics, formulas, and characteristic quantities connected to this configuration family.
6. Click the Condition tab, and create a new record (F5).
7. In the Value 1 field, enter GDCOLOR or select the GDCOLOR row from the Characteristic tab.
8. In the Rel. Op field, select the Equal To relational operator.
9. In the Value 2 field, select GREY from the List of Values. (The values in this list change depending on the characteristics that you selected as Value 1. You choose the value that corresponds to this component. In this case, the corresponding value is GREY because it is connected to Component 150, Grey Paint.)
10. Save your changes.
11. Repeat the above steps for the 151 and 152 components, selecting BLACK and WHITE, respectively, for the Value 2 field.
12. For evaluation of the rule(s), see the Creating Interim Order exercise below.

Creating Configuration Actions

Purpose: The purpose of this exercise is to define configuration actions, to explain when to use the actions, and to see the result of added actions.

Prerequisites: A configuration structure must exist (IE–11), as must a configuration family with connected characteristics (EASYFLEX).

Windows:
Configuration Structure,or
Configuration Structure Graphic

Note: Once you have created your configuration structure and conditions, it is time to define the actions required to obtain the correct structure and routing. A Set action is often used to handle the dynamic data that are dependent on lot size, such as machine run factor or quantity per assembly. You use the Declare action to specify other characteristics that are used only to control the production Back Office Characteristics but are a consequence of the option that the customer has chosen. The rules (condition/action) will be defined in the same way regardless of the element to which the rule is attached. You can define rules for the element's configuration structure alternative, routing alternative, components, operations, work guidelines, and tools.

1. Open the Configuration Structure window, and query (F3) for the IE–11 part on site 1.
2. Select the * (asterisk) alternative.
3. Select the Component 150 line, because you will add an action to this component.
4. Right-click and then click Configuration Structure Rules.
5. Review the part information. On the tabs, you can see the characteristics, formulas, and characteristic quantities connected to this configuration family.
6. Click the Action tab, and create a new record (F5).
7. In the Action field, select Set from the list.
8. In the Item field, select Quantity Per Assembly from the List of Values. (This is the item to which you will attach the Set action. Note that the values in the list change depending on the action selected.)
9. In the Value field, either enter LPAINT or select the LPAINT from the Formulas tab. LPAINT is a formula that calculates paint consumption.
10. Save your changes. Note that the quantity per assembly changes depending of the size of the garage door.
11. Repeat the above steps for the 151 and 152 components.
12. For evaluation of the rule(s), see the Creating Interim Order exercise below.

Creating Interim Order

Purpose: The purpose of this exercise is to show you how to create and use an interim order.

Prerequisites:A configuration structure must exist, as must a configuration family with connected characteristics and configuration rules for the configuration structure or routing.

Windows:
Interim Demand Header

Note: The interim order has several functions. For CTO, the most important of these is to verify or simulate the configuration rules and structure. These two functions can be done whenever desired or when there is a change in a rule or formula. Another function is to calculate the cost for the specified configuration. This can be done on the interim order header or from the customer order or quotation using an interim order. 

1. Open the Interim Demand Header window.
2. Create a new interim order on site 1 (F5), and enter a description.
3. In the Part No field, enter 11. Also enter a demand quantity and a required date.
4. Save your changes.
5. In the header, right-click, point to Configuration, and then click Create.
6. Enter your configuration by defining the values for the characteristics. All required characteristics are visible and need to receive a value. Optional characteristics must be added from the list before a value can be defined. If the characteristics have required quantities, you must specify the quantity of each characteristic that you want. When finished, click OK. The Evaluate Rules window appears.
7. Select the Complete Log Evaluation Criteria, and click OK. 
8. The evaluation is made, and the structure and interim order (s) are created. The interim order(s) have more information about each subpart or component, and you can use the right mouse button menu to open the interim order. 
9. The structure appears in the Tree Structure tab. Verify that all components that should be included in the configuration are actually in the structure. Example: If you defined White for the GDCOLOR characteristic, the 152 part number, White paint, should be included, etc.
10. Always look at the result log. This log contains all messages that the system has generated for this configuration (errors, warnings, or information). To try to pinpoint what data generated the message, look on the Detail, Component, and Operation tabs in the Interim Demand Header window. (The other tabs, Supply detail and Supply Overview, are used for IFS/Constraint Based Scheduling).
11. When you have checked the result log and the structure is correct, you can calculate the cost by right-clicking in the Interim Demand Header window, and then clicking Calculate Cost. This step is optional in the production flow since you can perform the calculation in DOP. However, it provides useful information for the simulation.
12. The cost must be saved as the standard cost for this configuration. Right-click and then click Save Standard Cost. You are prompted to indicate whether you want to save the cost. Click Yes. Information appears about the saved cost for the configured part(s).
13. If this part should be produced, transfer the interim order to DOP by right-clicking and then clicking Create DOP.