Overview of MTO Manufacturing Data—Overview Exercises

Basic Data Setup

Inventory Part

Purpose: The purpose of this exercise is to set up the inventory parts on your site for running Make To Order (MTO) functionality using racing engine data.

Windows:
Copy Parts To Site
Background Jobs

Note: If you already have these racing engine parts copied to your site, you do not need to do this exercise. These parts all have part numbers with the format of 22-nnn.

1. Open the Copy Parts To Site window.
2. In the From area, enter 1 in the Site field.
3. Enter 220 in the Comm. Group 2 field. The parts belonging to commodity group 220 have part numbers with the format 22-nnn.
4. In the To area, enter your site in the Site field.
5. Click OK.
6. Wait for the background job to complete. When it finishes, the parts will be copied to your site.

Inventory Part Planning Data

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

Windows:
Inventory Part /Planning Data

If you already have the planning data for the racing engine parts in your site, use your existing parts.

1. Set the values to the values in the tables below in the Inventory Part/Planning Data tab.

General exercise for Manufactured Inventory Part

General exercise for Purchased Inventory Part

Inventory Part Supply Type and DOP Connection

Purpose: The purpose of this exercise is to set up the supply type and DOP connection settings for three of your inventory parts on your site for running MTO functionality using racing engine data.

Windows:
Inventory Part/Planning Data
Inventory Part/Acquisition

1. Set the values to the values in the table below in the Inventory Part/Planning Data tab.

2. Set the values to the values in the table below in the Inventory Part/Acquisition tab.

Note: You must set the supply type first to be able to set the DOP connection. You can set both values before saving the records.

General exercise for Manufactured Inventory Part

General exercise for Purchased Inventory Part

Inventory Part Estimated Material Cost

Purpose: The purpose of this exercise is to set up the estimated material cost for the purchased inventory parts on your site for running MTO functionality using racing engine data.

Windows:
Inventory Parts

If you already have the material costs for the racing engine parts in your site, use your existing parts.

Note: If you query for your site, using lead time code of Purchased, and part numbers that match 22-%, the records returned should be in the same order as in the table below. Moving the Estimated Material Cost column close to the Part No. column will make it easier to check your place in the list. Some of the values contain decimal components.

1. Set the values to the values in the table below in the Inventory Parts window.

General exercise for Manufactured Inventory Part

General exercise for Purchased Inventory Part

Part Revision and Product Structure

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

Windows:
Product Structure
Product Structure

If you already have the product structures for the racing engine parts in your site, use your existing structures.

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 site 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 below to your site by right-clicking and then clicking Copy Structure Revision.
2. Important: Be sure to copy both alternatives for the 22-110 part.
3. Set the structure alternate(s) for the part just copied to your site to Buildable.
4. Repeat for another part until all manufacturing structure revisions have been copied.

General exercise for Copying Revisions

Work Center

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

Windows:
Work Center

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

1. Copy the work centers in the table below 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 in the table below.

General exercise for Setting Up Work Center

Labor Class

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

Windows:
Manufacturing Labor Class

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

1. Copy a labor class from site 1 in the table below to your site. Use the duplicate command to make it easier.
2. For the labor class that you have copied to your site, set the costs for cost sets 1 and 2 to the values from the table below.
3. Repeat for another labor class until all have been copied.

General exercise for Setting Up Labor Class

Manufacturing Tool

Purpose: The purpose of this exercise is to set up the manufacturing tools on your site for running MTO functionality using racing engine data.

Windows:
Manufacturing Tool

If you already have the manufacturing tools for the racing engine parts in your site, use your existing manufacturing tools.

1. Copy the manufacturing tools in the table below from site 1 to your site. Use the duplicate command to make it easier.

General exercise for Setting Up Manufacturing Tool

Routing Revision

Purpose: The purpose of this exercise is to set up the routing revisions for running MTO functionality using racing engine data.

Windows:
Routing

If you already have the routings for the racing engine parts in your site, use your existing routings.

1. Copy the manufacturing routing revisions for the parts in the table below from site 1 to your site by right-clicking and then clicking Copy Routing Revision.
2. Important: Be sure to copy both alternatives for the 22-110 part.
3. Set the routing alternate(s) for the part just copied to your site to Buildable.
4. Repeat for another part until all manufacturing routing revisions have been copied.

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 site first and then change the revision number to match the source revision number. Otherwise, an overlapping date range may result. In addition, the Routing Type will default to a value other than Manufacturing if another value exists. Verify that the Routing Type is Manufacturing.

General exercise for Copying Revisions

Manufacturing Lead Time

Purpose: The purpose of this exercise is to set up the manufacturing lead time for the inventory parts on your site for running MTO functionality using racing engine data.

Windows:
Lead Time Calculation
Cumulative Lead Time Calculation
Background Jobs

If you already have the manufacturing lead time for the racing engine parts in your site, use your existing manufacturing lead time.

1. Calculate the manufacturing lead time for all the parts in your site. Use average capacity and the maximum time of machine or labor.
2. Verify that the background job completed without error.
3. Calculate the cumulative lead time for all the parts in your site.
4. Verify that the background job completed without error.

General exercise for Calculating Manufacturing Lead Time

Part Cost

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

Windows:
All Parts Cost Calculation
Copy Costs To Cost Set One
Background Jobs

If you already have the racing engine parts in your site, use your existing parts.

1. Calculate the costs for all the parts in your site for cost set 2.
2. Verify that the background job completed without error. View the details to check that the messages are all normal.
3. Copy the costs from cost set 2 to cost set 1 your site.

Note If you get messages about zero cost for the discrete racing engine parts, check to see if any of the possible problems listed at the end of the main exercise is the cause.

4. Verify that the background job completed without error. View the details to check that there are no messages about zero cost not being allowed for the parts.

General exercise for Part Cost Calculation

Sales Part

Purpose: The purpose of this exercise is to set up a sales part on your site for running MTO functionality using racing engine data.

Windows:
Sales Part

If you already have the sales part in your site, use your existing part.

1. Create a new record in the Sales Part window.
2. Enter the 22-110 in the Sales Part Number field.
3. Enter a price of $5,000.00.
4. Using the List of Values, enter values in the Sales Price Grp, Sales Group, and Discount Group fields.
5. Save the record.

General Exercise for Sales Part

Inventory Location

Purpose: The purpose of this exercise is to set up an inventory location to receive parts into inventory for netting.

Windows:
Inventory Locations

If you already have the inventory location in your site, use your existing location.

1. In the Inventory Locations window, query for your site.
2. In the table window area, create a new record.
3. Enter a value in the Location No and Warehouse fields.
4. Optionally, enter values in the Bay, Row, Tier, and Bin fields.
5. Enter a value in the Location Name field.
6. Using the List of Values, enter a value for the Location Group field, using any value with an Inventory Location Type of Picking.
7. Save the record.

General Exercise for Inventory Locations

Main Exercise

Purpose: The purpose of this lesson is to understand how the racing engine is built.

Windows:
Structure Graphic
Structure Graphic/Graphical Structure
Inventory Part
Inventory Part/Cost
Inventory Part/Manufacturing
Part Cost

View MTO Racing Engine

1. Query for part number 22-110 and your site in the Structure Graphic window.
2. If the record for revision 1 of the manufacturing structure is not selected, select it.
3. Right-click on part number 22-110 in the Structure GraphicGraphical Structure tab and then click Expand Descendents to view the complete structure.
4. Verify that each of the alternates is in Buildable state.
5. Query for part number 22-110 and your site in the Inventory Part window.
6. In the Inventory Part/Cost tab, verify that the inventory value is 4083.41.
7. In the Inventory Part/Manufacturing tab,  verify the values in the following fields: Cum. Leadtime is 3, the Fixed Leadtime by Day is 0.0875, the Variable Leadtime by Day is 0.2375, the Fixed Leadtime by Hour is 0.7, and the Variable Leadtime by Hour is 1.9.

Note: If the values in the steps below do not match, results in some of the MTO exercises will not match. This may not be important if the exercises concerning DOP costs or scheduling will not be performed. To correct the values, the problem is likely to be one of the following:

• If Cum. Leadtime is zero, but the other lead time values are not zero, then the Order Cumulative Lead Time Calculation step was not completed.
• If all of the lead time values are zero, then the Manufacturing Lead Time steps were not completed.
• If the Inventory Value is zero, then the part cost steps were not completed.
• The planning method was not set to K or P for one or more of the appropriate parts. This might affect both cost and lead time.
• One or more of the Estimated Material Cost values were not set correctly. This would affect cost, but not lead time.
• One or more of the product structures were not copied or were not set to Buildable. This would affect both cost and lead time.
• One or more of the routings were not copied or were not set to Buildable. This would affect both cost and lead time.
• One or more of the work center cost values were not set correctly. This would affect cost, but not lead time.
• One or more of the labor class cost values were not set correctly. This would affect cost, but not lead time.

Note: It may be helpful to compare the part cost of the parts in your site with those in site 1 using the Part Cost window if it is difficult to find the source of the discrepancy.