Course Description for Discrete Manufacturing

This course provides information on using the discrete manufacturing functionality in IFS/Shop Order. This course includes the following topics:

• Introduction to discrete manufacturing
• Creating and using shop order requisitions
• Performing batch balancing on shop order requisitions
• Creating shop orders
• Planning shop orders
• Handling shop orders
• Handling component material
• Handling operations
• Receiving shop orders
• Analyzing shop orders
• Transferring shop order accounting transactions to finance
• Using Material Review Board (MRB) with shop orders
• Handling shop orders for configure to order (CTO) products
• Using Part Ownership
• Execute multilevel repair
• Basic data and requirements for discrete manufacturing

Prerequisites

The estimated time to complete this course is 43 hours and 30 minutes. Before taking the lessons in this course, you should have basic knowledge about inventory, manufacturing standards, and how to work and navigate in IFS Applications.

The estimated time to complete the Basic course is 13 hours. The prerequisite courses are Maintain Inventory Basic and Manufacturing Standards Basic.

The estimated time to complete the Intermediate course is 34 hours and 30 minutes. The prerequisite courses are Manufacturing Standards Intermediate and Maintain Inventory Intermediate.

The estimated time to complete the Advanced course is 21 hours. The prerequisite courses are Manufacturing Standards Intermediate, Maintain Inventory Intermediate, Define CTO Basics Intermediate, Master Scheduling Intermediate, and the MRP chapter of the Make to Stock Planning Intermediate course.

Course Length

The estimated time to complete this course is 43 hours and 30 minutes.

Target Audience

This course was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Introduction

This chapter provides an introduction and overview of the discrete manufacturing process using IFS/Shop Order. These introduction lessons provide information you need before beginning the lessons in the other chapters.

This chapter contains the following introductory lesson:

• Discrete Manufacturing Activities - Learn the purpose of shop order requisitions and shop orders. Understand, in a general way, the type of activities you will do in the discrete manufacturing process.
• Manufacturing Terms and Principles - Learn the definitions of manufactured product, by-product, substitute part, material, operation, subcontracting, and other manufacturing terms.
• Overview of Discrete Manufacturing Data - Learn various manufacturing structure and routing situations used in discrete manufacturing. Set up the discrete racing engine data that will be needed throughout most of this course. This lesson is mandatory for all lessons in this course, except for the Batch Balancing Shop Order Requisitions lesson and the Handling Shop Orders with CTO Products lesson.
• Overview of Multilevel Repair Data - Set up the multilevel repair data that will be needed throughout the execute multilevel repair course.

This chapter has the following key lesson:

• Discrete Manufacturing Process - Learn status changes for a shop order from creation to closure.

Prerequisites

Before taking the lessons in this chapter, you should have completed the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have a basic knowledge about working and navigating in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 4 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Creating Shop Order Requisitions

This chapter covers the information you need to know to create and view shop order requisitions.

This chapter contains the following introductory lesson:

• Introduction to Creating Shop Order Requisitions - Learn the purpose and types of shop order requisitions.

This chapter has the following key lesson:

• Creating Shop Order Requisitions Manually - Learn how to create shop order requisitions.

This chapter has the following extended lessons:

• Viewing Shop Order Requisitions Created By Master Scheduling - Learn to recognize shop order requisitions created by the IFS/Master Scheduling process.
• Viewing Shop Order Requisitions Created By MRP - Learn to recognize shop order requisitions created by the IFS/MRP (material requirements planning) process.
• Viewing Shop Order Requisitions Created By Reorder Point - Learn to recognize shop order requisitions created by the reorder point process.
• Creating Shop Order Requisitions for Next Level Demand - Learn how to create shop order requisitions and purchase requisitions for next level demand components. 

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have a basic knowledge about working and navigating in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 5 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Batch Balancing Shop Order Requisitions

This chapter explains how to use the batch balancing functionality to reduce waste of common components.

This chapter contains the following key lesson:

• Batch Balancing Shop Order Requisitions - Learn why and how you would use batch balancing with shop order requisitions to reduce waste of common components.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 1 hour.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Creating Shop Orders

This chapter explains how to create regular, repair and prototype shop orders.

This chapter contains the following key lessons:

• Releasing Shop Order Requisitions - Learn how to create shop orders using the most common method, which is to release a shop order requisition.
• Creating Shop Orders Manually - Learn how to create a regular shop order manually when needed, skipping the creation of a shop order requisition.
• Connecting Shop Orders to Project Activities - Learn how to connect and disconnect a shop order to and from a project activity in IFS/Project.

This chapter has the following extended lesson:

• Creating Repair Shop Orders - Learn how to manually create a repair shop order to fix or re-manufacture parts in stock.
• Creating Prototype Shop Orders - Learn how to manually create a prototype shop order to test a new trial version of a product that is planned to be manufactured.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 2.5 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Planning Shop Orders

This chapter explains the various IFS/Shop Order functions that help you effectively plan the production of your shop orders.

This chapter contains the following key lessons:

• Performing Availability Analysis on Shop Orders - Learn how to determine whether you have sufficient material to reserve or issue to a shop order before releasing the order to production.
• Releasing Shop Orders - Learn how to release shop orders so you can control the order of manufacturing and control when subcontracting operations are done.

This chapter has the following extended lessons:

• Canceling and Parking Shop Orders - Learn how to delete a shop order from the system and how to put a shop order on hold.
• Processing Shop Orders Automatically - Learn how to use the IFS/Shop Order automatic processing functionality that can save you time by allowing the system to automatically convert shop requisitions to shop orders, release shop orders, and reserve shop orders.
• Scheduling and Rescheduling Shop Orders Using the Advanced Planning Board - Learn how to use the Advanced Planning Board to schedule shop orders on non-Constraint Based Scheduling (CBS) sites or sites for which the Scheduling Server has been disabled.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 5.5 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Handling Shop Orders

This chapter covers how to handle shop orders in various situations and for specific production needs.

This chapter contains the following key lessons:

• Changing Shop Order Information - Learn how to change the information on a shop order to exactly match what is needed for production and how to add informational document text to print on reports.
• Handling By-products on Shop Orders - Learn how to define and handle by-products on a shop order when you want to receive and track in inventory any additional material that was produced as a result of manufacturing the main product.

This chapter has the following extended lessons:

• Handling Work Guidelines on Shop Orders - Learn how to provide electronic instructions about material or operations to personnel working on shop orders.
• Handling Tools on Shop Orders - Learn how to track the assignment and usage of tools for management and maintenance purposes, how to identify tools as resources that are used in Constraint Based Scheduling (CBS), and how to use tool guidelines.
• Closing Shop Orders - Learn how to manually and automatically close shop orders and in what situations you might use each method. 
• Entering Preposting Shop Orders - Learn how to use preposting to override the standard posting controls when the rules for the standard posting controls do not fit the accounting rules needed for the shop order.
• Handling Serial Numbers on Shop Orders - Learn how to create shop orders for serialized parts and how to reserve serial numbers for receipt on a shop order.
• Merging and Splitting Shop Orders - Learn how to merge or split shop orders to manually optimize production, adjust for changes in supply or demand, and adjust for changes necessary to handle rework or scrap. Learn how to use split checklists to ensure that established procedures are followed when splitting shop orders.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 6 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Handling Material

This chapter covers information related to reserving and handling the component materials needed for shop order production.

This chapter contains the following key lessons:

• Changing Shop Order Material - Learn how to change component material when you want to build older revisions or variants, when you must service a specific need or request, and when you will use substitute parts.
• Reserving Material on Shop Orders - Learn how to reserve all the material on a shop order with a single transaction, how to select specific parts from specific locations to assign to the shop order, and how to reserve material for specific work centers.
• Issuing and Unissuing Material on Shop Orders - Learn how to issue or unissue shop order material.
• Report and Unreport Component Scrap on Shop Orders - Learn how to report and unreport component scrap on shop orders.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 2 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Handling Operations

This chapter explains how to handle and report on shop order operations, including how to handle outside (subcontracted) operations.

This chapter contains the following key lessons:

• Changing Shop Order Operations - Learn how operations are assigned to a shop order and how to add, modify, or delete an operation on a shop order.
• Reporting Operations on Shop Orders - Learn how to report work on operations so that personnel managing the shop orders know the detailed status of an order as each activity is recorded against it and they can ensure that costs are assigned to the appropriate accounts as activity is recorded for an operation.

This chapter has the following extended lesson:

• Handling Shop Order Subcontracting - Learn how to create external work centers, how to create external operations in a routing, how to process a shop order with external operations, and how to ship work in process (WIP) to a supplier for processing.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 2 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Receiving Shop Orders

This chapter includes lessons about how to receive parts into inventory, how to reverse the receipts when necessary, and the various situations that affect receipt.  

This chapter contains the following key lessons:

• Receiving Shop Orders Automatically - Learn how to streamline the processing of basic shop orders through production by automatically receiving the shop order lot into a predetermined inventory location.
• Receiving Shop Orders Manually - Learn how to manually receive a shop order, selecting the inventory location and the specific quantity to be received after the shop order parts are completed. 
• Unreceiving Shop Orders - Learn how to use the unreceive function so that material that was moved into inventory from a shop order receipt can be reversed back into work in process (WIP). 

This chapter has the following extended lessons:

• Receiving By-products on Shop Orders - Learn how to receive by-products on shop orders into inventory to track any additional material produced as a result of manufacture of the main product. 
• Receiving Substitute Parts on Shop Orders - Learn how to receive substitute parts on a shop order when production requires that a part other than the originally-specified part be used.
• Receiving Reserved Serial Structures on Shop Orders - Learn how to create and modify serial structures, how to use serial number reservation, and how to receive serialized parts on a shop order. 

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter and the Handling Shop Orders chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 5 hours.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Analyzing Shop Orders

This chapter explains where to find and analyze shop order data so that you can resolve productions problems and set up more efficient processes.

This chapter contains the following key lesson:

• Analyzing Shop Orders - Learn how to monitor shop orders to determine deviations to costs, to help determine where to focus on cost reductions, to better control business performance, and to identify which shop orders are generating problems and what data is available for finding the potential causes. Learn how to find transaction history for shop orders.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 1 hour.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Transferring Transactions

This chapter explains how to transfer shop order accounting transactions to finance.

This chapter contains the following key lesson:

• Transferring Shop Order Processing Transactions to Finance - Learn how to transfer accounting transactions to finance in order to simplify the posting of accounting transactions, taking advantage of the integration between IFS/Shop Order and IFS Financials.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 1 hour.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Using Material Review Board (MRB)

This chapter explains how to use a Material Review Board (MRB) with a shop order. MRBs provide a structured mechanism to mark production material for review due to possible non-conformity, allowing users to maintain a history of inspection activities and results for individual parts or orders and to create MRB checklists, which provide a standard set of actions to take or issues to look for during an inspection. 

This chapter contains the following key lesson:

• Entering and Handling MRB on Shop Orders - Learn how to generate a Material Review Board (MRB) for a shop order that may contain non-conforming material, how to disposition material on an MRB, and how to use approval checklists for MRBs. 

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 1 hour.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Handling Shop Orders for CTO Products

This chapter explains how to create and handle shop orders for configure to order (CTO) products.

This chapter contains the following key lesson:

• Handling Shop Orders with CTO Products - Learn when and how you can use shop orders for configure to order (CTO) products. 

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, Define Distribution Basics and Define CTO Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 1 hour. 

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Using Part Ownership

This chapter explains how to define and handle part ownership on shop orders, including the shop order product, material and by-products.

This chapter contains the following key lesson:

• Handling Part Ownership on Shop Orders - Learn how to define part ownership for the shop order product, material and by-products, and how part ownership affects shop order material actions.

Prerequisites

Before taking the lessons in this chapter, you should have completed the Introduction chapter in this course and the IFS courses for Manufacturing Standards, Maintain Inventory, and Define Distribution Basics. In addition, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 1 hour. 

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.

Execute Multilevel Repair

This chapter explains how to perform multilevel repair using shop orders.

This chapter contain following key lessons:

• View Multilevel As Built Structure - Learn how to view the full level as-built structure in graphical view.
• Create Multilevel Repair Shop Order - Learn how to create a multilevel repair shop order and the conditions to be satisfied to create such orders.
• Reserve & Issue Parent Materials - Learn how and when to reserve/issue parent materials and the consequences of un-reserving/un-issuing parent materials. 
• Validate Structure Components - Learn how to match the as built data with the actual structure received using correct repair actions.
• Change Structure Components - Learn how to change the existing as-built structure using correct repair actions.
• Reserve & Issue Component Materials - Learn how to reserve and issue components which were added to the structure due to structure changes.
• Revert Structure Changes - Learn how to revert a structure change done.
• Receive Multilevel Repair Shop Order - Learn how to receive salvage parts & the repaired parent parts. You will also learn about the changes done to the old as built data and how the new as built data are generated.

Prerequisites

Before beginning the lessons in this chapter, you should have a basic understanding of manufacturing concepts. Also, you should have completed the other lessons in discrete manufacturing course.

Chapter Length

The estimated time to complete this chapter is 4 hours and 15 minutes. 

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and engineers.

Basic Data and Requirements

This chapter covers the basic data and requirements necessary for discrete manufacturing only. It does not cover basic data and requirements necessary for inventory and manufacturing standards. 

Links to the Basic Data and Requirements lessons appear as appropriate in other lessons throughout the course, so by the time you have finished the previous chapters in the course, you may have already covered the lessons in this chapter.

This chapter contains the following basic data lessons:

• Creating Shop Order Priority Codes - Learn how to create shop order priority codes and how the priority codes are used by shop orders.
• Creating Split Checklist Templates and Split Reason Codes - Learn how to create split check lists and split reason codes for splitting shop orders.
• Creating MRB Checklist Templates and MRB Codes - Learn how to create MRB check lists and MRB codes for use with MRB headers.
• Creating Repair Reasons - Learn how to create repair reason types and repair reasons for a specific site.

Prerequisites

Before taking the lessons in this chapter, you should have basic knowledge about how to work and navigate in IFS Applications.

Chapter Length

The estimated time to complete this chapter is 1 hour and 15 minutes.

Target Audience

This chapter was designed primarily for shop order planners, shop floor operators, production managers, and production schedule planners.