Repetitive Manufacturing - Exercise 2

Basic Data Setup

You should have performed the Repetitive Manufacturing - Exercise 1 before you start this exercise. In that exercise, basic data is set up and those will be used in this exercise

BDR Exercise for Repetitive Manufacturing 1

Create Inventory Locations for Work Centers

Purpose: The purpose of this exercise is to show you how to create locations that will be used by work centers.

Windows:
Inventory Locations

  1. Open the Inventory Locations window.
  2. Create two new records, named WCI and WCO as Location number and enter the information from the table below.
Parameter Values for WCI Values for WCO
Warehouse 1 1
Bay 3 4
Row — —
Tier — —
Location name Work C Inb. Work C Outb.
Location Group Choose a location group where the inventory location type is Picking. Choose a location group where the inventory location type is Picking.
  1. Save the records.

Create Inventory Parts

Purpose: The purpose of this exercise is to show you how to create inventory parts that will be used by a production line

Windows:
Inventory Part

  1. Open the Inventory Part window.
  2. Create new inventory parts, named 61-901 and 61-999 in your site. Enter the information from the table below.
Parameter Values for 61–901 Values for 61–999
Part Description Sport Aluminum Rim Aluminum work piece
Part Type Manufactured Purchased
Planner * *
U/M PCS PCS
Supply Type Schedule Order
Estimated material cost - 150 (see the Costs tab)
  1. Save the records.

Create Work Centers

Purpose: The purpose of this exercise is to show you how to create work centers that will be used by routings and a production line.

Windows:
Work Center

  1. Open the Work Center window.
  2. Create new work centers named 910 and 920 for your site. Enter the information from the table below.
Parameter Values for 910 Values for 920
Description Milling Balancing
Production Line (the Detail tab) 900 900
Locations (the Location tab) Add your inbound location (WCI) and your outbound location (WCO). In Location Usage column, select Inbound and Outbound respectively. Add your inbound location (WCI) and your outbound location (WCO). In Location Usage column, select Inbound and Outbound respectively.
  1. Save the Information.

Create a Routing

Purpose: The purpose of this exercise is to show you how to create a routing for Part 61–901.

Windows:
Routings

  1. Open the Routings window. Query for the part 61-901 in your site.
  2. In the Routings tab, create a routing in which Part 61–901 has two operations: Operation 10, with Work Center 910; and Operation 20, with Work Center 920.
  3. Make the routing buildable.

Create a Product Structure

Purpose: The purpose of this exercise is to show you how to create work centers and then create a product structure.

Windows:
Product Structure

  1. Open the Product Structure window. Query for the part 91-901 in your site.
  2. In the Product Structure tab, create a structure where Part 61–901 is made from 61–999 and quantity per assembly is one.
  3. Connect part 61–999 to Operation 10.
  4. Make the routing buildable.

Cost Calculation

Purpose: The purpose of this exercise is to show you how to create inventory value for the parts so that production receipt can be performed in later exercises. It is important that you have at least an estimated material cost for the purchased part (see the Create Inventory Parts section).

Windows:
All Levels Part Cost Calculation
Copy Cost Set To Cost Set One

  1. Open the All Levels Part Cost Calculation window.
  2. Select your site, Part 61–901 and Cost Set 2 from the List.
  3. Click OK.
  4. Open Copy Cost Set To Cost Set One window.
  5. Select your site, From Cost Set 2 and Part 61-901 from the list. Select Include Components check box.
  6. Click OK.

Connect Part to a Production Line

Purpose: The purpose of this exercise is to show you how to add a part that can use report points when reporting production

Windows:
Production Line

  1. Open the Production Line window.
  2. Query for the Production Line 900. That is the production line for rims.
  3. In the Part tab, add Part 61–901.
  4. Click Sched Report Point tab. Add a report point. Enter 10 in Last Operation No column.