Overview of Quality Management Data—Introductory Exercises

Basic Data Setup

Inventory Parts

Purpose: The purpose of this exercise is to set up the inventory parts at your site for use in the Quality Management exercises.

Menu Path: Inventory/Inventory Part/Copy Parts To Site
General/Background Jobs

1. Open the Copy Parts To Site window.
2. In the From area, enter 1 in the Site field.
3. Enter 290 in the Comm. Group 2 field. The parts belonging to commodity group 290 have part numbers with the format 29-nnn.
4. In the To area, enter your site in the Site field.
5. Click OK.
6. Open the Background Jobs window and verify that the background job is completed. When it is finished, the parts will have been 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 at your site.

Menu Path: Inventory/Inventory Part/Inventory Part

1. Open the Inventory Part window and click the Planning Data tab.
2. Set the values in the respective fields to the values shown in the table below.

General Exercise for Purchased Inventory Part

General Exercise for Manufactured Inventory Part

Inventory Locations

Purpose: The purpose of this exercise is to set up the inventory locations at your site.

Menu Path: Inventory/Inventory Location/Overview – Inventory Locations

1. Open the Overview – Inventory Locations window.
2. Query for your site.
3. Enter the inventory locations as shown below.

General Exercise for Purchased Inventory Part

General Exercise for Manufactured Inventory Part

Part Revisions and Product Structures

Purpose: The purpose of this exercise is to set up the part revisions and product structures at your site.

Menu Path: Manufacturing Standards/Structures/Product Structure

Note: The destination revision number will automatically be changed from the source revision number to the next higher integer. Therefore, you must change the site to your site and then change the revision number to match the source revision number. In addition, the Structure Type field will default to a value other than Manufacturing if another value exists. Verify that the structure type is Manufacturing.

1. Open the Product Structure window
2. Copy the manufacturing structure revision from site 1 for the first part shown in the table below to your site by right-clicking in the header and then clicking Copy Structure Revision. The Copy Structure Revision window appears.
3. Under Destination Revision, enter your site and change the revision number to 1. Then click OK.
4. On the Product Structure tab, right-click just above the Alternative field and then click Build to change status for the structure alternate for the part you just copied to your site to Buildable. 
5. Repeat the procedure for the other parts until all manufacturing structure revisions have been copied.

General Exercise for Copying Revisions

Production Line

Purpose: The purpose of this exercise is to set up the production line at your site.

Menu Path: Manufacturing Standards/Work Centers and Production Lines/Production Line

1. Open the Production Line window and create a new record.
2. In the Production Line field, enter 29-M. In the Description field, enter Milling Line.
3. In the Site field, select your site from the List of Values.
4. Save the record.
5. Click the Part tab and create a new record.
6. In the Part No field, enter 29-523, with Rocker Arm as its description. Then save the record.
7. Click the Location tab and create a new record.
8. Select location 29 ROCKER ARM INB from the List of Values. 
9. In the Location Usage field, set the value to Inbound. Then save the record.
10. Create a new record.
11. Select location 29 ROCKER ARM OUT from the List of Values. 
12. In the Location Usage field, set the value to Outbound. Then save the record.

Work Centers

Purpose: The purpose of this exercise is to set up work centers at your site.

Menu Path: Manufacturing Standards/Work Centers and Production Lines/Work Center

1. Open the Work Center window.
2. Copy the work centers shown in the table below from site 1 to your site by right-clicking and then clicking Copy Work Center.
3. 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 below.

General Exercise for Setting up Work Centers

Manufacturing Tools

Purpose: The purpose of this exercise is to set up the manufacturing tools at your site.

Menu Path: Manufacturing Standards/Manufacturing Standards Basic Data/Basic Data for Manufacturing Tool

1. Open the Basic Data for Manufacturing Tool window.
2. Copy the manufacturing tools in the table shown below from site 1 to your site. Use the Duplicate command (F6) to make it easier.

General Exercise for Setting up Manufacturing Tools

Purchased Parts

Purpose: The purpose of this exercise is to set up the purchased part for services at your site.

Menu Path: Purchasing/Purchase Part/Purchase Part

1. Open the Purchase Part window.
2. Copy the purchased part for services shown in the table below from site 1 to your site.  Use the Duplicate command (F6) to make it easier.

General Exercise for Purchased Parts

Routing Revisions

Purpose: The purpose of this exercise is to set up routing revisions.

Menu Path: Manufacturing Standards/Routings/Routing

Note: The destination revision number will automatically be changed from the source revision number to the next higher integer. 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 field will default to a value other than Manufacturing if another value exists. Verify that the routing type is Manufacturing.

1. Open the Routing window.
2. Copy the manufacturing routing revision for each part shown in the table below from site 1 to your site by right-clicking in the header and then clicking Copy Routing Revision. Be careful to copy only the default alternate.
3. On the Routings tab, right-click and set the routing alternate for each part you just copied to your site to Buildable.

General Exercise for Copying Routing Revisions

Subcontracting Costs

Purpose: The purpose of this exercise is to set up the subcontracting costs for outside operations at your site.

Menu Path: Manufacturing Standards/Routings/Subcontracting Cost

1. Open the Subcontracting Cost window.
2. If you have not already done so for the subcontracting costs at your site for the record shown below, set the costs for cost sets 1 and 2 to the values indicated below.

General Exercise for Subcontracting Operations

Manufacturing Lead Time

Purpose: The purpose of this exercise is to set up the manufacturing lead time for the inventory parts at your site.

Menu Path: Manufacturing Standards/Calculations/Order Manufacturing Lead Time Calculation
Manufacturing Standards/Calculations/Order Cumulative Lead Time Calculation
General/Background Jobs

1. Open the Order Manufacturing Lead Time Calculation window.  
2. Calculate the manufacturing lead time for all the parts at your site. Use average capacity and the maximum time of machine or labor.
3. Open the Background Jobs window and verify that the background job completed without error.
4. Open the Order Cumulative Lead Time Calculation window.
5. Calculate the cumulative lead time for all parts at your site.
6. Return to the Background Jobs window and verify that the background job completed without error.

General Exercise for Calculating Manufacturing Lead Time

Part Costs

Purpose: The purpose of this exercise is to set up the costs for the manufactured inventory parts at your site.

Menu Path: Costing/Cost Calculations/Calculate Part Cost – All Levels
Costing/Cost Calculations/Copy Costs To Cost Set One
General/Background Jobs

1. Open the Calculate Part Cost – All Levels window.
2. Calculate the costs for all levels of the valve train (part no. 29-220) at your site for cost set 2.
3. Open the Copy Costs To Cost Set One window.
4. Copy the costs from cost set 2 to cost set 1 for the 29-% parts at your site. (Enter 29-% in the Part No field. All 29-XXX parts will be copied.)
5. Open the Background Jobs window and verify that the background job completed without error. View the details to verify that there are no messages about zero cost not being allowed for the parts.

General Exercise for Part Cost Calculation

Main Exercises

Viewing the Discrete Manufacturing Racing Engine

Purpose: The purpose of this exercise is to view the entire racing engine structure.
Menu Path: Manufacturing Standards/Query – Structures/Structure Graphic
Manufacturing Standards/Routings/Routing
Inventory/Inventory Part/Inventory Part

1. Open the Structure Graphic window.
2. Query for part no. 29-220 and your site.
3. If the record for revision 1 of the manufacturing structure is not selected, select it.
4. Click the Graphical Structure tab. Then right-click on part no. 29-220 and click Expand Descendents to view the complete structure.
5. Verify that all structures have an alternate with Buildable status.
6. Open the Inventory Part window, and query for part no. 29-220 and your site.
7. Click the Costs tab and verify the inventory value. If the inventory value is zero, the part cost steps were not completed properly.
8. Open the Routing window, and query for part no. 29-220 and your site. Verify that all routings have an alternate with Buildable status.

Entering a Supplier for Purchased Parts

Purpose: The purpose of this exercise is to enter suppliers for two purchased parts.
Menu Path: Purchasing/Purchase Part/Supplier for Purchase Part

1. Open the Supplier for Purchase Part window.
2. Create a new record.
3. Enter part no. 29-OSP.
4. Select supplier 29-001, AAA Heat Treat, from the List of Values.
5. Enter a purchase price of 10.
6. Save the record.
7. Place the cursor in the header and create a new record.
8. Enter part no. 29-320, Valve Cover.
9. Select supplier 29-002, Mag Cast, Inc., from the List of Values.
10. Enter a purchase price of 50.
11. Save the record.

General Exercise for Supplier for Purchased Part

Copying a Control Plan for Manufacturing

Purpose: The purpose of this exercise is to copy a control plan for Manufacturing.
Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing

1. Open the Control Plan – Manufacturing window.
2. Query for part no. 29-321, Camshaft. Select control plan no. 100001, revision 3.
3. Right-click in the header and then click Copy Control Plan. A window appears.
4. Under Destination Revision, enter information in the following fields: Control Plan No, Site (your own site), Responsible Person, Part No, Part Revision, Routing Revision, Routing Alternative No, Phase In Date, and Phase Out Date.
5. Click OK. A new control plan is created.
6. You receive the following message: Control Plan XX and Revision XX is Created. Do you want to view it now? Click Yes. A new Control Plan – Manufacturing window appears.
7. In the Routing Operation No field on the Control Plan Line tab, add 30 from the List of Values.
8. Save the record.
9. Right-click in the header and then click Checklist. A window appears.
10. Select the check boxes in the Item Approved field for all checklist items.
11. Click Save and then click Close.
12. Right-click in the header of the Control Plan – Manufacturing window and then click Active.
13. Verify that the control plan status has been changed to Active.
14. Repeat steps 2 through 13 for part no. 29-721, Camshaft (Serial Handled). Select control plan no. 100002, revision 3.
15. Repeat steps 2 through 13 for part no. 29-821, Camshaft (Lot/Batch Handled). Select control plan no. 100003, revision 3.
16. Repeat steps 2 through 13 for part no. 29-523, Rocker Arm. Select control plan no. 100004, revision 1. However, in the Routing Operation No field on the Control Plan Line tab, add 10 from the List of Values.

Copying a Control Plan for Purchasing

Purpose: The purpose of this exercise is to copy a control plan for Purchasing.
Menu Path: Quality Management/Control Plan/Control Plan – Purchasing

1. Open the Control Plan – Purchasing window.
2. Query for part no. 29-320, Valve Cover. Select control plan no. 100006, revision 1.
3. Right-click in the header and then click Copy Control Plan. A window appears.
4. Under Destination Revision, enter information in the following fields: Control Plan No, Site (your own site), Responsible Person, Part No, Supplier No, Phase In Date, and Phase Out Date.
5. Click OK. A new control plan is created.
6. You receive the following message: Control Plan XX and Revision XX is Created. Do you want to view it now? Click Yes. A new Control Plan – Purchasing window appears.
7. Right-click in the header and then click Checklist. A window appears.
8. Select the check boxes in the Item Approved field for all checklist items.
9. Click Save and then click Close.
10. Right-click in the header and then click Active.
11. Verify that the control plan status has been changed to Active.
12. Repeat steps 2 through 11 for part no. 29-OSP, Camshaft, Heat Treated. Select control plan no. 100005, revision 1.

Copying a Control Plan for Inventory

Purpose: The purpose of this exercise is to copy a control plan for Inventory.
Menu Path: Quality Management/Control Plan/Control Plan – Inventory

1. Open the Control Plan – Inventory window.
2. Query for part no. 29-521, Intake Valve. Select control plan no. 100007, revision 2.
3. Right-click in the header and then click Copy Control Plan. A window appears.
4. Under Destination Revision, enter information in the following fields: Control Plan No, Site (your own site), Responsible Person, Part No, Phase In Date, and Phase Out Date.
5. Click OK. A new control plan is created.
6. You receive the following message: Control Plan XX and Revision XX is Created. Do you want to view it now? Click Yes. A new Control Plan – Inventory window appears.
7. Right-click in the header and then click Active.
8. Verify that the control plan status has been changed to Active.