Creating Routing—Exercises

Required Data

Creating Inventory Part

Purpose: The purpose of this exercise is to show you how to set up the inventory parts on your site for running functionality using racing engine data.

Windows:
Copy Parts to Site

Note: If you already have the racing engine parts in your site, use your existing parts. These parts all have part numbers with the format of 20-nnn.

1. Copy all parts from Site 1 to your site using 200 as the value for Commodity Group 2.

Creating Product Structure

Purpose: The purpose of this exercise is to show you how to set up the part revisions and product structures on your site for running functionality using racing engine data.

Windows:
Product Structure
Note: If you already have the product structures for the racing engine parts in your site, use your existing structures.

Note: The following steps will be done once for each of the parts in the table below.

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 own and change 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. Verify that the structure type is Manufacturing.

1. Copy the manufacturing structure revision from Site 1 for a part in the table above to your site by right-clicking and then clicking Copy Structure Revision.
2. Set the structure alternate for the part that you just copied to your site to Buildable.
3. Repeat for another part until all manufacturing structure revisions have been copied.

Creating Work Center

Purpose: The purpose of this exercise is to show you how to set up the work centers on your site for running functionality using racing engine data.

Windows:
Work Center

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

Note: The following steps will be done once for each of the work centers in the table below.

1. Copy the work centers in the table above from Site 1 to your site by right-clicking and then clicking Copy Work Center.
2. For each work center that you have copied to your site, set the costs for Cost Sets 1 and 2 to the values shown in the table above.

General exercise for Copy Work Center

Creating Labor Class

Purpose: The purpose of this exercise is to show you how to set up the labor classes on your site for running functionality using racing engine data.

Windows:
Manufacturing Labor Class

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

Note: The following steps will be done once for each of the labor classes in the table below.

1. Copy a labor class from Site 1 in the table above to your site. Use the Duplicate command (F6) to make this easier.
2. For the labor class that you copied to your site, set the costs for Cost Sets 1 and 2 to the values from the table above.
3. Repeat for another labor class until all have been copied.

Entering the Operation Usage Factor (Only for Configurable Parts)

Purpose: The purpose of this exercise is to show you how to set up the basic data on your site for running functionality involving the entering of the operation usage factor (only for configurable parts).

Note: Replace the XX in the exercises below with your initials. This ensures uniqueness and makes it easier to locate your data. For example, John Smith would prefix his data with the letters JS.

1. If you have not already done so, create a configurable part, XX–14, in the part catalog, and set it to Configurable.
2. Connect the part to Configuration Family EASYFLEX in the Config Part Catalog tab. You are prompted to indicate whether you want to copy all characteristics to the part specification revision.
3. Click Yes.
4. Create Inventory Part XX–14 with the Manufactured part type on your site.
5. In the Inventory Part/Planning Data tab, change the supply type to DOP.
6. Create a configuration structure for the part that you just made with the components listed in the table below.

   Line Item No.	Component Part	Qty per Assembly
   1	156	3.8
   2	157	3.8
   3	158	3.8
   4	155	1

General exercise for Creating Configuration Part

General exercise for Creating Inventory Part

Main Exercises

Purpose: The purpose of these exercises is to show you how to create your own routing and to understand the effects of some of the setup data used in the routing.

Windows:
Manufacturing Standards/Routings/Routing

Creating Routing

1. Open the Routing window.
2. Query for Part 20–250 on your site.
3. Use the * (asterisk) alternative.
4. Create new lines.
5. Enter the operations shown in the table below.

   Operation No.	Description	Work Center	Machine Set up time	Machine Run Factor	Factor Unit
   10	Assemble Part	300	1	0.4	Hours/Unit
   20	Adjust Fittings	650	0	0.2	Hours/Unit

6. Save your changes.
7. To be able to see any results of the information entered, you can run a lead time calculation. Right-click and then click Calculate Manuf Lead Time (average and machine time only). 
8. Change the data for machine run factor, and perform a new calculation.
9. Save your changes.
10. For one of the operations, change the factor unit. 
11. To be able to see any results of the information entered, you can run a lead time calculation. Right-click and then click Calculate Manuf Lead Time ( average and machine time only). 
12. For one of the operations, change the information in the Parallel Operation field.
13. For one of the operations, select the Milestone Operation check box.
14. To be able to see any results of the information entered, you can run a lead time calculation. Right-click and then click Calculate Manuf Lead Time ( average and machine time only).  

General exercise for Calculation of Lead Time

Adding Labor Class to the Operation

1. Open the Routing window.
2. Query for Part 20–250 on your site.
3. Use the * (asterisk) alternative.
4. On Operation 10, add a labor class. Select 1 from the List of Values.
5. Enter a labor run factor of 0.2.
6. Once you have entered a labor class, the crew size must be entered before saving. If necessary, you can also enter a value for employee competency profile in the Emp Comp Profile field.
7. If specifying setup labor time, enter values in Setup Labor Class and Setup Crew Size fields. Use the List of Values to select from available labor classes. If necessary, you can also enter a value for employee setup competency profile in the Emp Setup Comp Profile field.
8. To be able to see any results of the information entered, you can run a lead time calculation. Right-click and then click Calculate Manuf Lead Time ( average and machine time only).

General exercise for Calculation of Lead Time

Entering the Operation Usage Factor (Only for Configurable Parts)

1. Open the Routing window.
2. Query for Part XX–14 on Site 1.
3. Use the * (asterisk) alternative.
4. Add operations as shown in the table below.

   Operation No.	Description	Work Center	Machine Set up time	Machine Run Factor	Factor Unit	Operation Usage Factor
   10	Cut to specified width	DM–A	0	200	Units/hour	0.6
   11	Cut to specified width (steel)	DM–A	0	150	Units/hour	0.4
   20	Mount protective plate	DM–A	0	200	Units/hour	1

5. By using the usage factor on the operation, you estimate the percentage that an operation will be selected. This is also used in the lead-time calculation. In this case, 40% of the customers will buy a garage door that has a steel finish.
6. To be able to see the result when you change the op usage factor, you have to calculate the lead time.

Note: If the operation belongs to a certain component, you may want to enter an operation usage factor corresponding to that component.

General exercise for Calculation of Lead Time