Optional Prerequisites for Shop Floor Tracking:

The Shop Floor Tracking Module is used to record detailed transactions of all of the user’s Work In Process (WIP) activity.  This screen is a critical piece in the communication process.  This allows production to update the system as products move through the shop floor.  Production can add notes and indicators to identify current issues and delays.  This information is readily available for program managers and others so they have important information when it is needed and without chasing it down in production.

From within this module, the following functions are available, depending on the user’s configuration:

For further detail of these functions see Article #3107 . 

To Enter the Shop Floor Tracking by Work Order Module depress Production/Shop Floor Tracking by Work Order

The Main Screen will appear.

Depress the Find Button displays the following sequences:

Select the desired Work Order record.

The Shop Floor Tracking screen is then populated with the appropriate data.

The Products will be listed in alpha-numerical order, along with the Revision, Class, Type and Description.

Select the desired Product Number.

Find the desired Work Order record within the system.

Highlight the current Work Center where quantity is displayed, as illustrated: 

 

Depress the “Transfer” button. The system will prompt for a password. The following dialogue box will be displayed. The user may elect to transfer material within work centers (WC) or within activities (A) by pressing the appropriate radial button on the screen. Manex will determine the next area to transfer product based on the product routing, and enter the location in the “To:” field. The user may elect to change this location by pressing the down-arrow button next to the field and selecting a different location.(NOTE: The user MUST have "Skip rights" or "Supervisor rights"  setup within the Security module in order to skip work center locations, or move product backwards)

Next, Manex lists the number of products at the current location. The user may move all items, or select the quantity to be moved. This may be done by simply over-writing the quantity or by using the “arrows” to raise or lower the quantity shown. The user may also elect to print a traveler to accompany the parts at this time. Once the Print Traveler box is checked, a Footnote button appears, as shown.   Any Footnotes that a person enters within this screen is just temporary and is only printed on the Traveler report.    The user may also elect to print a label to accompany the parts to material to finished goods, identifying the work order, product date, work center, etc.   If the user elects to have the “Pop up printer Selection dialog” marked. The system will not print directly to the default printer. It will then bring up the Printer dialog box and allow the user to select which printer to send the traveler to.

Depressing the Footnote button will bring up a note screen.

Depress the Edit button, Type in the footnote. Depress the Save button. Depress the Exit button.

Depress the OK button. The material will transfer and the Traveler will go directly to the default printer. (This report requires that the user have the bar code font available).

If a balance still remains in the selected work center then the system will prompt the user if they would like to transfer to a different Work Center. Yes – will bring up the Transfer Material screen again. No – will bring you back to the regular Shop Floor Tracking module.

If the product is included in an active Cycle count, or Physical Inventory count, the following message will appear after depressing the OK button on the transfer screen anud user  will not be allowed to transfer product until the count has been completed and posted.



If user is transfering product into FGI and the Work Order has any item(s) that has short qty > 0 and the "Ignore Kit" box is NOT checked the following message will popup giving the user the option to continue moving the product or not.   





Transferring Serialized product

 

If the work station being used to transfered serialized material is assigned to use a default work center in Production Work Center/Activity Setup module, when the user first opens the module, the module will use the default work center assigned for this workstation, if the transfer is "FROM" a different work center other than the default and user is NOT a supervisor or has the  option "Allow Changing Default Work Center for Serial Number Transfer" box checked within the Security module, they will receive the following message:

 

When user depresses "OK"  a supervisor approval is required to continue.  After supervisor’s password is entered, the default work center will be changed to the one that the supervisor entered password for.   For example:  the workstation is assigned to use “TU” as default work center, now if user chooses to use “AI” to transfer, the system will ask for supervisor’s password, if user cancels the password, the default work center will still be “TU”, but if the supervisor enters his/her password on this machine, the default work center will be changed to “AI”.  If now the user tried to transfer from “TU” again, the system will ask for supervisor’s password again.  If user exits the module and come back, the default work center will be “TU” again.

If the user is tracking by serial numbers, and if the user is transferring a lesser quantity than displayed, Manex will display a screen from which to select the serial number(s) to be moved in the transaction.

The user may select one or more serial numbers to match the quantity being transferred, and then press the OK button.

The user must select the proper number of serial numbers or the transaction will be cancelled. 

Since less is being transferred, the following message will appear: Yes – will bring up the Transfer Material screen again. No – will bring you back to the regular Shop Floor Tracking module.

 

Discussion on the Accounting Entries

If the user also has accounting installed, then the appropriate journal entries will forward to the Accounting “Release to General Ledger” screen. Briefly, assuming that the user has the material cost set up in the Inventory Control Item master, then when the product reaches the Work Center “Finished Goods Inventory”, the entry will be to debit Finished Goods Inventory (or the warehouse home general ledger number of the product) and to credit WIP .If the product ended up in the Work Station “Scrap”, then the debit would be to the default scrap general ledger account, as set up in the Accounting Set Up.

Configuration Variance

If the Material Cost per the product was not equal to the sum of the standard costs per the BOM components, then a configuration variance will be created.

Please refer to the “Wip Value" Article #913 for further explanation.

To obtain reports, depress the Report button.  The following screen will appear:

JOB TRAVELER REPORT

Highlight the “Job Traveler” report. Make the desired selections in the Detail Report Section.

Then depress the Options tab. The following screen will appear:

Select the desired radial selection:Customer, Product or Work Order.   Select the desired Customer and Work Order by using the Down Arrows next to the fields.

If you do not want time in decimal format, uncheck the box.   The following reports will be displayed:

SERIAL NUMBER LIST FOR WORK ORDER BY WC/ACTIVITY REPORT

Highlight the “Serial Number List for Work Order by WC/Activity” report.   Depress the Options tab.   The following screen will appear:

Select the desired radial selection:Customer, Product or Work Order.    Select the desired Customer and Work Order by using the Down Arrows next to the fields.

The following report is available:

WORK ORDER LIST CONNECTED TO THE SERIAL NUMBER REPORT

Highlight the “Work Order List Connected to the Serial Number” Report.  Note:that this report is a View screen only – no report will be generated as an output.

Depress the Options tab.  Type in the Serial Number and the following will display.

Hitting the OK button will bring you back to the Shop Floor Tracking module.

TRANSFER HISTORY REPORT

Highlight the “Transfer History” report.

Depress the Options tab. The following screen will appear:

Select the Work Center by highlighting and depressing the > button.  If all Work Centers are desired, depress the >> button. If you do not want time in decimal format, uncheck the box.

Enter in the desired Date Range.   Leading zero's for SN will be removed from report.    The following Report will be displayed.

WORK ORDER WORK CENTER NOTES REPORT

Highlight the “Work Order Work Center Notes” report.

Depress the Options tab.  The following screen will appear:

All Work Centers are selected by default.   If you wish to deselect any Work Centers use the < Button.    The following report will be displayed:

SERIAL NUMBER TRACKING HISTORY REPORT

Highlight the “Serial Number Tracking History” report. 

Depress the Options tab.The following screen will appear:

Select the desired radial button:  Single Entry or Range.    Enter Serial Number.  Leading zero's for SN will be removed from report.

The following report will be displayed:  This report will gather transfer history and defect history for those serial numbers that have been linked to more than one work order and display the transfer history and defect history for all those work orders.   

Test & Repair Management (T&R) has been designed to capture testing results and failure information such as: In-circuit Testing, Sub-Assembly Functional Testing and System Final Assembly Testing.

Once this information has been entered this will allow the users the ability to see the Serial Number History and view all of the testing and repair results as well as when it had been shipped to customers.  It will also keep track of any associated returns or warranty work that had been done against this particular Serial Number, continuing history as long as the unit is in service. 

Overview: Manex Manufacturing System Software has bar code scan and print capability which is designed primarily for transfer of products in shop floor tracking and input of inspection data by serial number and defect code.

Installation: Bar Code Shop Floor Tracking is an extra cost option; it is not a part of the Core Manex MES modules.

Upon purchase of the module, Manex will send a soft key to activate the module.

• After activation, Bar Coding access for each user must be setup in the Manex Security module.  Users with “supervisor’s rights” will automatically have access.  See Article #3250 if you would like to scan the employee id rather than having the employee enter password each time. 
• Each client workstation (individual PC) which will be printing Reports, Travelers, labels, Serial Tags, Physical Inventory Tags and Defect Lists with Bar Coding must have the font installed as an active Windows font.
• If Bar Coding of Serial Numbers is desired, the Serial Numbers must be setup in the Work Order Serial Number Control module. 

Specification:

1. Manex uses the Microsoft Trutype BC C 39 Narrow Font. See Article #1225  for Bar Code installation procedure.   
2. Use of a Y-type keyboard-emulation scanner is supported by Manex.  The scanner output goes into Manex via the keyboard-input cable. Bar code fields may be scanned or manually entered with the scanner installed.
3. There is no restrictions on the scanner you use as long as it can read Code39 it will work.  It also must be a keyboard wedge since we do not offer batch processing. Most scanners require ¼” of white space surrounding the bar code. Laser and inkjet printed labels must have adequate resolution, contrast and clarity to print barcodes that are readable. If you are having problem with your scanner, make sure your scanner isn't set to scan Code39 extended.
4.  Manex recognizes a bar code by an asterisk (*) at the beginning and end of the bar coded field.

Enter the Shop Floor Tracking by Bar Code module.

The following screen will be displayed:

Depress the Xfer button. Type in your password or scan employee id .  

The user can either enter in the Work Order number (which will then display the Product and Rev) or go to the Bar Code Tracking Method section and enter in the Serial Numbers desired. The system will then default the Work Order #, Product and Rev onto the screen.

The Bar Code Tracking method is dependant on how it is setup within the Shop Floor Tracking Defaults .

The Work Order number, Serial No., Quantity, From Work Center and To Work Center or from Work Center to Activity will display, depending on the selection within SFT Defaults to Transfer by WC or Activity. 

Depress the Save button.

 

 

 

If the work station being used to transfer serialized material is assigned to use a default work center in Production Work Center/Activity Setup module, when the user first opens the module, the module will use the default work center assigned for this workstation, if the transfer is "FROM" a different work center other than the default and user is NOT a supervisor or has the  option "Allow Changing Default Work Center for Serial Number Transfer" box checked within the Security module, they will receive the following message:

 

 

 

When user depresses "OK"  a supervisor approval is required to continue.  After supervisor’s password is entered, the default work center will be changed to the one that the supervisor entered password for.   For example:  the workstation is assigned to use “TU” as default work center, now if user chooses to use “AI” to transfer, the system will ask for supervisor’s password, if user cancels the password, the default work center will still be “TU”, but if the supervisor enters his/her password on this machine, the default work center will be changed to “AI”.  If now the user tried to transfer from “TU” again, the system will ask for supervisor’s password again.  If user exits the module and come back, the default work center will be “TU” again.

 

 

 

The Work Order Module is used to record the details required for initiating assembly of products.

Work Order Tab field definitions

Work Order	The number assigned to the Work Order.
Order Date	The date the Work Order was created.
	The status of the Work Order:  Standard;   Priority-1;   Priority-2;   Firm Plann;   Admin Hold;   Mfg Hold;   Rework;   ReworkFirm;   or   Cancel.  The system defaults to Standard. Standard is the ordinary work order status.  Priority is set up as a make ahead of all other orders, 1 being the most important and 2, the second most important.  Firm Plann, lets MRP know that the Work Order decision is intentional and NO action is required.    Admin Hold is an order on hold due to customer credit, etc (this will NOT interfere with the kitting, production or shipping).  Mfg Hold WILL prevent the order from being put In-Process, Kitted, or Assembled. Note:  If the WO is put on Mfgr Hold before being put In-Process no demands will be displayed in MRP. Rework is to fix or redo a previous order. Rework Firm or Cancel.   Firm Plann = Example: The requirement may be 100 but the Firm Plann WO is only for 60. Normally in this case if the WO status was standard MRP would instruct user to increase the WO qty from 60 to 100 to fulfill the requirement of 100.  But since the WO is Firm Plann, MRP will take no action.   See defintion for DUE DATES below for further detail.   If user changes the Work Order Status to Admin Hold or Mfgr Hold, a box will appear on the Work Order Screen (as shown below) giving the user the option to put the Work Order on MRP Hold.  If the user does NOT check this box, orders that are In-Process will not be affected in MRP. Manufacturing hold on a Work Order will disallow movement of the parts through SFT.     Rework = users will use this status if they do not want to have it included as available to meet demands. ReworkFirm = users will use this if they want to have it included as available to meet demands.  The only thing is that they will have to be sure the due dates for a rework firm precede any demand that was created to use those parts.    NOTE:  Work Orders originated from an RMA Receiver will have "ReworkFirm" Job Status and users will NOT be allowed to change the Job Status. Since the material issued to the RMA is likely to be a defective assembly, or requires re-inspection, the work order must be completed by either transferring the material to FGI or to scrap to close the work order.  Therefore, an RMA work order cannot be cancelled.  Also, users will NOT be allowed to edit or change the Bld qty because when product is brought into the system with an RMA Receiver it is then automatically issued as itself to the kit at that time.
Serialized	If this box is checked, the completed units must be assigned unique serial numbers.
Customer Name	The name of the customer for which this Work Order applies. If BOM is assigned to specific customer, and if there is CONSG part in the BOM -- Only that customer will be available in the WO customer list If BOM is assigned to specific customer, and no CONSG parts in the BOM -- Default to that customer, but all other customers are available to be selected. If BOM is not assigned to specific customer, all customer should be available.
Forecast Item	The Forecast checkbox is defaulted as True whether or not there actually is a forecast.  By doing this, we minimize the possibility of the MRP double ordering parts for the SO. If there is a forecast, then the SO will be subtracted from it. If there isn’t a forecast, the SO will drive as usual. Users can change to un-checked in the Sales order/Work order if desired.
Sales Order	A Sales Order number will be displayed if the Work Order was created within the Sales Order Mgmt module. If you are entering a Work Order through the Work Order module, you can manually link an existing Sales Order to the Work Order. Only if the Sales Order and Work Order is for the same customer and same product number.   Keep in mind though that even if you have the SO linked to a WO does not mean that the quantities will always be the same.  The link is for reference only between the two modules and they are still individual records so when any changes are made to either the SO or the WO the change will not update or be carried forward to the other.  A message is displayed to the users that they will have to make the same changes to the WO.
Class	The classification of the product to be assembled.
Type	The type with the classification of the product to be assembled.
Part Number	The number of the make part to be assembled
(Rev)	The revision number pertaining to the part number.
Description	The description of the part to be assembled.
Work Order Released	If this box is unchecked, you are able to kit the work order but you will not be allowed to process the material through SFT.  Once this box has been checked, you will be able to move the material through SFT.  If user is using the WO checklist feature this box will not be checked until all checkpoints including the "Kit Complete" have been marked off.  Once the "Kit Complete" checkpoint has been checked the WO Released checkbox will be checked automatically.
(Date)	The date the Work Order was released.
Due Date	This is the date by which the completed assembly must be completed.  Note:  The Sales Order Ship Date must be the same or later than the Work Order completion date. MRP will look at the SO Ship Date which should be the same or precede the WO Due Date by the transit time from your dock to the Customer’s dock. The SO Ship Date becomes the Work Order due date when the Work Order is created from the Sales Order, but user may change this date.  MRP will recognize the WO as being due in time for the SO ship date, and therefore include the work order as supply to meet the sales order demand, whether or not it’s kitted.  If the Work order is kitted and then the dates are moved (either in the sales order ship date to a later date or the work order due date to an earlier date), then MRP will not view the work order (supply) as meeting the sales order (demand).  If the work order has been kitted, and thus changed status to a firm planned work order (as far as the MRP module is concerned), then MRP will NOT suggest adjusting the work order delivery date to meet the demand, but WILL suggest creating a new work order (or moving a non-firm planned work order) and ordering the parts for the new work order date.  So the keys are the work order due date, and the sales order ship date.  The former must be the same or precede the latter, to keep the work order identified as supplying the product for the sales order.  User does have the ability to turn off the function of the Sales order driving the demands for the MRP and just use the Work Order for buying components by checking the MRP on Hold box in the Sales Order module per line item.    Note:  The Kitted BOM Cost calculations displayed on the "Kit to Close Report" is based off the WO Due date and compares that to the EFF/OB dates on the BOM.  So users need to be VERY careful with the WO Due Dates and make sure that they stay current along with the EFF/OB dates on the BOM.
Build Qty	The number of units which must be completed.
Completed	The number of units already completed.
Balance	The number of units which still must be completed.
	Depressing this button will display the applicable Work Order Check List (shown below).
	Depressing this button will display the applicable Work Order Notes

Work Order Schedule Field definitions

Schedule

Due Date	The date by which the completed assembly must be ready for shipment
Schedule Quantity	The amount of quantity scheduled for that due date
Total	The total of all of the scheduled quantities
	Depressing this button will allow the user to add a line
	Depressing this button will allow the user to Delete a line

 Automatic Scheduling

First Due date	The date of the first shipment
Delivery Quantity	Quantity per each shipment
/Day/Wk/Mo	The increments per each schedule, either Day, Week or Month
	This allows the user to have MANEX schedule each shipment

Note:  Keep in mind that this is for your reference only - this screen does not affect any other portion of the ManEx system.  

Indented Work Order Tree field definitions

Work Order	The number assigned to the Work order.
	Depressing this button allows the user to associate this work order with its parent work order.
	Depressing this button allows the user to delete the parent work order association.

Parent Work Orders

Work Orders

Enter Production/Work Order Managment/Work Order Mangement Module

The following screen will apear:

When the screen first opens, the user is limited to only four of the eight action buttons shown: Find an existing Work Order, Add a new Work Order, Print a report, or Exit.

Pressing the Find Action Button displays the following sequences: User may choose to find or search for an existing order: by entering the Work Order Number, by entering a Product Number, by entering a Customer Name, or by entering a Sales Order Number.

If the user elects to find an order by the Work Order Number, a screen appears listing work orders in numerical order, along with the Part Number and Customer name. User has the option to view Open orders only or All orders. The user selects the work order by either entering it into the red box, or scrolling down the list and clicking on the selected order. The Work Order screen is populated with the appropriate data.

When the user elects to find an order by the Product Number, a screen appears listing part numbers in numerical order. The user selects the part number by either entering it into the red box, or scrolling down the list and clicking on the selected part.
A list of all of the Work Orders assigned to the selected part is shown in numerical order, along with the customer name, Due Date and Build Qty. The user finds a work order by either entering it into the red box, or scrolling down the list and clicking on the selected work order.   The Work Order screen is populated with the appropriate data.

If the user elects to find an order by the Customer, a screen appears listing customers in alphabetical order. The user selects the customer by either entering it into the red box, or scrolling down the list and clicking on the selected order.
A list of all of the selected customer’s orders are shown in numerical order, along with the customer name, Due Date and Build Qty.  The user selects the work order by either entering it into the red box, or scrolling down the list and clicking on the selected order. The Work Order screen is populated with the appropriate data.

When the user elects to find an order by the Sales Order Number, a screen appears listing open Sales Orders in numerical order. The user selects the Sales Order by either entering it into the red box, or scrolling down the list and clicking on the selected order.
A list of all of the Work Orders assigned to the selected sales order is shown in numerical order, along with the part number, revision, class an type.  The user finds a work order by either entering it into the red box, or scrolling down the list and clicking on the selected work order.   The Work Order screen is populated with the appropriate data.

Enter Production/Work Order Management/Work Order Management Module

The following screen will appear:

To ADD a new work order, depress the Add Action button.  The user is first prompted for the appropriate password:

The following screen appears: You may find a Product Number directly (see all parts), or limit the field by selecting a Part Class code first.

If the user selects the by "Product Number” button, a pop-up screen listing all of the part numbers appears.  Select the part by typing the part number into the red box or highlighting and double clicking.
If the user selects the by "Part Class" button the find part class screen appears.  Select the Part Class by typing the part class into the red box or highlighting and double clicking.
After selecting the part class to be entered, the Find Part screen appears, but only includes those parts with the selected class code inventory type. Select the part by typing the part number into the red box or highlighting and double clicking.

Note:  If the Product Number you are looking for does not appear in the Find screens listed above you may want to check the Part Source of the Product number you are looking for.  ManEx does not allow a Work Order to be created for a Make/Buy Product,  (due to MRP calculating incorrect demand and showing incorrect message with safety stock). 

 And the screen is populated with information about the part number.

If the work order numbering is set to manual, the first prompt is for the Work Order Number. MANEX will enter the current system date as the Order Date, and the user may revise the date if desired

The next field to enter is the Job Status. Clicking on the down-arrow on the right side of this field activates a pop-up screen providing a list of status from which to select. The system defaults to Standard. Standard is the ordinary work order status.  Priority is set up as a make ahead of all other orders, 1 being the most important and 2, the second most important.  Admin Hold is an order on hold due to customer credit, etc.  Mfg Hold would prevent the order from being kitted and assembled.  Rework is to fix or redo a previous order (See Article #1520), Rework Firm or Cancel.  The user may put orders on Admin or Manufacturing Hold without affecting MRP. Manufacturing hold on a Work Order will disallow movement of the parts through SFT. Rework = users will use this status if they do not want to have it included as available to meet demands. ReworkFirm = users will use this if they want to have it included as available to meet demands.  The only thing is that they will have to be sure the due dates for a rework firm precede any demand that was created to use those parts.

Serial Number box. If this box is checked, the units must have a unique serial number assigned. (Note: Serial numbers are assigned in the Work Order Serial Number Control Module).

Sales Order Number. A Sales Order number will be displayed if the Work Order was created within the Sales Order Mgmt module. If you are entering a Work Order through the Work Order module, you can manually link an existing Sales Order to the Work Order. Only if the Sales Order and Work Order is for the same customer and same product number.   Keep in mind though that even if you have the SO linked to a WO does not mean that the quantities will always be the same.  The link is for reference only between the two modules and they are still individual records so when any changes are made to either the SO or the WO the change will not update or be carried forward to the other.  A message is displayed to the users that they will have to make the same changes to the WO.  

The next field to enter is the CUSTOMER.  When Adding a new Work Order, the user may select a Customer from the pull down or begin entering the customer name, and ManEx will immediately begin tracking the key-entry to bring up the customer with as few keystrokes as necessary to identify the customer. If there is no customer to be associated with the order, the user may select Standard price.    If the Part Number selected is setup in the Sales Price List Information module the customers from the customer list within this module will be the only customer(s) to appear in the pull down.   If BOM is assigned to specific customer, and if there is CONSG part in the BOM -- Only that customer will be available in the WO customer list If BOM is assigned to specific customer, and no CONSG parts in the BOM -- Default to that customer, but all other customers are available to be selected. If BOM is not assigned to specific customer, all customer should be available.

If the work order is ready to start being moved through SFT (material obtained and shortages at a minimum), then the user may check the Work Order Released box, which will allow the material to be moved through Shop Floor Tracking. If MRP is used, the demand for the material will be generated, but the work order cannot begin production. To see a list of unreleased work orders, request Back Log Report by Work Center as discussed in the Reports section. 

After that, the user enters a Due Date for the order (the date due of finished goods), and the Build Quantity. The shipped quantity will be set to zero, and the balance due to the same as the work order build quantity. 

Work Order Schedule Tab

After all the information has been entered in the Work Order screen, depress the WO Schedule tab. The following screen will appear:   Note:  Keep in mind that this is for your reference only - this screen does not affect any other portion of the ManEx system.  

There are two modes available for completing a scheduled delivery for a product: Automatic and Manual. In the Automatic mode, MANEX will take a beginning date and a quantity to be delivered each period (Days, Weeks or Months) and schedule out the delivery. 

The following activities are available:

Automatic Scheduling. Pressing this button enables the scheduling box and places the default lead time date in the 1st Due Date box. (The user may establish a default number of days in the System Setup.) The user can then use that date, or enter the first (beginning delivery) date the customer expects to receive the order. The WO Schedule tab allows the user to divide the shipment into multiple deliveries of equal parts. For example, if the order is for a total of 100 pieces, and the customer wishes delivery to be at the rate of 10 units each day, then the delivery quantity should be entered as 10. The next box allows the user to select the delivery intervals. The options are by day (DY), week (WK) or month (MO). 

After selecting the delivery interval, pressing the SAVE button creates a line for each delivery date in the sequence requested. 

In this WO Schedule tab, the user may further edit, delete or add lines. 

Manual Scheduling. Pressing the Add Line button enables the delivery schedule box and places the cursor in the Due Date box. The user can then enter the first (beginning delivery) date the customer expects to receive the order.  Next, the Ship Date (the date the order is to leave the user’s dock) will be entered by MANEX based on the transit days entered. This date can then be modified by the user if a different date is desired. Then the scheduled quantity is entered.  The Shipped quantity will be completed by MANEX when the line has material shipped against it.  Additional lines may be added or deleted by pressing the appropriate button. The total number of units scheduled will be displayed at the bottom of the box, so the user can verify all units have been scheduled. 

Indented Work Order Tab

If the user has multi-level products, and there are other work orders upon which the current work order depends having material, then the Indented Work Order tab will allow the user to establish relationships between those work orders and the current one.

 Depress the Add Parent Work Ord button. A red box will appear, as illustrated below:

Type the Parent Work Order number into the box.

After entering a valid work order, the user is presented with a screen completed with the work order information, but with a blank work order number (if numbering is manual). After entering the work order, the schedule and quantity, the new work order may be saved.

Once all information is entered, the user may either Save by depressing the Save Record action button, or Abandon Changes by depressing the Abandon Changes Action buttons.

Find an existing Work Order                                                    

After a Work Order has been found, it may be edited by selecting the Edit Action button.

All fields available for editing will be enabled for modification. The fields which may be edited are:

NOTE:  Work Orders originated from an RMA Receiver will have "ReworkFirm" Job Status and users will NOT be allowed to change the Job Status, due to the fact that when the Work Order is created from RMA module all kitting, serial number, .... records are created and if user changes the WO status the system may loose track of these records.  User will receive the following message if they try to change the job status on a Work Order that was originated from an RMA Receiver.  

     

Since the material issued to the RMA is likely to be a defective assembly, or requires re-inspection, the work order must be completed by either transferring the material to FGI or to scrap to close the work order.  Therefore, an RMA work order cannot be cancelled. 

The following message will be displayed to the user if a SO is linked to a WO:




NOTE:  The link is for reference only between the two modules and they are still individual records so when any changes are made to either the SO or the WO the change will not update or be carried forward to the other. 

Find the Work Order you want to cancel. 

Depress the Edit button and enter your password. 

Depress the arrow next to the Job Status and change the Job Status to Cancel as displayed below.

Depress the Save action button.

Note:  You can’t Cancel a Work Order that has been kitted.  If you must cancel a kitted Work Order, go into the Kitting & Shortage Mgmt module and de-kit the order.

 

 

 

NOTE: Work Orders originated from an RMA Receiver will have "ReworkFirm" Job Status and users will NOT be allowed to change the Job Status, due to the fact that when the Work Order is created from RMA module all kitting, serial number, .... records are created and if user changes the WO status the system may loose track of these records.  User will receive the following message if they try to change the job status on a Work Order that was originated from an RMA Receiver.

 

 

Since the material issued to the RMA is likely to be a defective assembly, or requires re-inspection, the work order must be completed by either transferring the material to FGI or to scrap to close the work order. Therefore, an RMA work order cannot be cancelled or re-opened.

 

 

Find a Closed Work Order  

Depress the Edit action button and change the Job Status from Closed to Standard

User will receive the following warning

Depress OK then Depress the Save record action button, The following message will be displayed to the user if a SO is linked to a WO:

To Manually Close Work Order

Find Work Order with Job Status anything other than "Closed"

Dperss the Edit action button (do not edit anything)

Depress the Save record Action button.  The following message will be displayed to the user if a SO is linked to a WO:

Depress Ok and Job Status will automatically change to Closed

NOTE: Work Orders originated from an RMA Receiver will have "ReworkFirm" Job Status and users will NOT be allowed to change the Job Status, due to the fact that when the Work Order is created from RMA module all kitting, serial number, .... records are created and if user changes the WO status the system may loose track of these records.  User will receive the following message if they try to change the job status on a Work Order that was originated from an RMA Receiver.

Indented Work Order Tab

If the user has multi-level products, and there are other work orders upon which the current work order depends having material, then the Indented Work Order tab will allow the user to establish relationships between those work orders and the current one.

Find an existing Child Work Order



Go to the Indented Work Order Tree tab.  Depress the Edit button. 

 Depress the Add Parent Work Ord button. A red box will appear, as illustrated below:

Type the Parent Work Order number into the box.  The Parent Work Order number will disappear and will not appear in the Work Order box until the Save record action button is depressed as displayed below.     Depress the Abandon  changes Action buttons to abandon changes.

 

 

 

Find the Parent Work Order, go to the Indented Work Order Tree tab and the Child Work Order linked will be displayed:

 

 

 

 

 

 

The Work Order Release Check List is originally developed in System Setup in the Shop Floor Tracking Defaults set up screen.    The Work Order Release Check List displays the following:  Work Order Number, Scheduled Ship Date, Part Number of the assembly, Revision Number pertaining to the assembly, Quantity in the Work Order and the Check List Items with information regarding items checked, by whom, the date and time.

Highlight the line you are interested in viewing.  The information at the bottom of the screen will display the check list items associated with the assembly.  If the item listed has been performed, there will be a check mark at the left of the item and the user may view the name of the person who performed the checking plus the date and time checked.

Enter Production/Work Order Management/Unreleased Work Order List Module  NOTE:  For this module to be available the "Use Work Order Checklist" box must be checked in the Shop Floor Tracking Default Screen in System Setup.

The following screen will appear:

Enter Production/Work Order Management/Open Work Order List Module    After activation, "Work Order Management" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.

The list of Open Work Orders displays the following:  Work Order Number, Customer Name, Sales Order Number, scheduled Due Date, Job Status (Standard, Priority, Administrative Hold, Rework, etc.), Build Quantity, Completed Quantity and Balance.

Selecting Open Work Order List will bring up the following screen:

Field Defintions

After activation, "Serial Number Setup" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.

The Work Order Serial Number Control Module is used to set up serial numbering for a particular Work Order.

Serial Number Setup Fields & Definitions

After Finding the Work Order.  The following screen will appear, listing the Work Order and Build Qty.  The Add record action button also becomes available.

Depress the Add record action button.  Type in the password.  Select Single Entry or Range method of assigning serial numbers by choosing the appropriate radial.

If you select Single Entry, the following screen will display, only allowing you to type in one Serial number at a time.

If you select Range, the following screen will display, allowing you to type in From and To Serial numbers. 

 

Note:  The system will force individual entry for serial numbers with prefixes or characters.  If user enters both character and number in one field, then it is hard to know which part (character or number) needs to be increased first. So the system cannot predict how the range is intended to increment: For Example if user enters a SN range of A101 to Z110. The system does not know how the user wants the range setup A101, B101, C101 or A101, B102, C103, etc.  

Depress the Save record action button and the range of numbers will populate on the left side of the screen.  As displayed below:  If you depress the Abandon changes action button the screen will abort and the serial numbers will not be saved.

Detail for Serial Numbers

To enter detail for serial numbers, highlight the pertinent serial number and then depress the Detail Tab. The following screen will appear:

Depress the Add a record action button, and the"Find by What?" screen appears:
If you depress the Manual button, the Detail screen appears and you may manually enter in a part number. If you depress the Inventory button, another selection screen will appear:
If you depress the Product Number button, a list of Product Numbers will appear.  To select the Product number either type it in the red box, or highlight the Product and double click on it.  The Inventory part number and revision selected will default in as displayed below.
If you depress the Part Class button,  a list of part classes will appear.  To select the Part Class either type it in the red box, or highlight the Part Class and double click on it.
A list of Parts will appear assigned only to that Part Class.  To select the Part either type it in the red box, or highlight the Part number and double click on it. The Inventory part number and revision selected will default in as displayed below.

Enter in Serial No and Comments if applicable.

Depress the Save record action button to save, or depress the Abandon changes action button to abandon changes.

Find an Existing Work Order. 

Depress the Edit action button.  Enter your password.

Receive the following message:

Depress OK and highlight the Serial number you would like to replace.

Type the correction into the Replace box. The Serial NO for that Sequence # will change.  Depress the Save changes action button to save changes, or depress the Abandon changes action button to abandon changes.

If you want to delete ALL of the Serial Numbers, depress the Delete action button. Then depress the Save changes action button. 

Invoking Serialization after the Work Order is Started

If you already have a Work Order started and then decide to invoke serialization, in order to assign serialization to a product with an open work order, in the Shop Floor Tracking Module, the parts must all be in a Work Center which is PRIOR to the Work Center in which serialization is to be applied.

Then the Work Center can be updated and the product moved BACK to the appropriate Work Centers after the product is serialized.   If the Work Order has been completed and the product is in the Finished Goods Work Center, the user may move the product back to a “non-serial Work Center” and then serialize and update the Work Order.  Then the user should move the parts back into the Finished Goods Work Center.  If the parts in Finished Goods were already shipped, the user can use the Inventory Handling module to temporarily increase the finished goods to the needed quantity. Then they can be backed into the Work Order.  After running these parts back down the chain, the user would use Inventory Handling to take the parts back out of inventory.

There is no easy way to have some work orders without serialization and some with for the SAME product.  Turning on Serial Numbers on a product with OPEN Work Orders must be done carefully.  Here are some processes:

1.  Using the same product and the SAME Revision – ship all of the non-serial numbered product PRIOR to turning on serialization OR don’t turn on serialization until you are ready to serialize everything not shipped.  To serialize everything not shipped, you will have to move product back to the Work Center where serialization is started, then turn on serialization in Work Order Traveler Setup (for further information see Article #1134) and click on the “Update Open Work Orders”.  Be sure to update all of the open work orders.  If you don’t, you won’t be able to ship anything that was not updated.  (The items will be in a black hole and will need a programmer to get them out.)

2.  Using the SAME Revision, but using the special character trick:

a.  Copy the product number to the new product in the Inventory Control item Master but put "00" in front of the Rev.  See Article #1058 for further instructions on copying a product number. 

b.  Then copy the existing product BOM to the new 00 revision product. See Article #1104  for further instructions on copying a BOM.

c.  Turn on serialization for the new 00 rev product and copy the routing from the old product.  Be sure to select which Work Center you want serialization to start. See  Article #1106 for further instructions on how to turn on the serialization. 

d.  Enter all new Sales orders using the 00 revision product number.

e.  When you have shipped all of the old non-serialized product, inactivate the product number in the Inventory Control module.  See Article #1058 for further instructions on how to inactivate a product number. 

3.  Using a different revision number:

a.  Copy the product number to the new product revision in the Inventory Control Item Master.  See Article #1058 for further instructions on copying a product number. 

b.  Then copy the existing product BOM to the new revision product.  See Article #1104  for further instructions on copying a BOM.

c.  Turn on serialization for the new revision product and copy the routing from the old product. Be sure to select which Work Center where you want serialization to start. See  Article #1106  for further instructions on how to turn on the serialization. 

d.  Enter all new Sales Orders using the revision product number.

4.  You may prefer to create new revisions using the ECO module.  It can change the revision of product in Work orders in WIP, but DO NOT turn on the serialization in the ECO module.  See Article #1133 for further instructions on the ECO module.

a.  First change the revision of the product using the ECO module

b.  Then move the product back to the Work Center where you want serialization to begin in the Shop Floor Tracking module.  See Article #1106 for further instructions on how to turn on the serialization. 

c.  Then turn on serialization and select “Update Open Work Orders” in the Work Order Traveler Setup and click on the “Update Open Work Orders”.   Be sure to update all of the open work orders.  If you don’t, you won’t be able to ship anything that was not updated.(The items will be in a black hole and will need a programmer to get them out.)

If the rework Work Order is created from RMA, then the user doesn’t need to assign the serial number for the Work Order.  The system will automatically transfer all serial numbers to the new re-work Work Order when the user creates the RMA Receiver.  For a complete discussion of the RMA process, please refer to Article #1610.

If the user MANUALLY creates a re-work Work Order, the following conditions for assigning existing serial number to a re-work Work Order will be:

1. Work Order MUST be a re-work Work Order.
2. There must have been sufficient quantity in FGI to issue to the re-work Work Order.
3. The serial number must match the part number issued.
4. The number of serial numbers to be issued must equal the number of parts issued.

When a Re-work Work Order is established for a serialized product, the user may select existing serial numbers that are in inventory (finished goods) that are to be reworked.  Rework Work orders will not accept NEW serial numbers.  When a serial number is placed in the rework Work Order, the serial number must exist in finished goods, and the number of serial numbers transferred to the Work order must equal the quantity of assemblies for the Work order.  The part number for the serial number that is moved into the rework Work Order does not need to be the SAME part number and revision as the rework Work Order.  Thus, if a user wants to upgrade part number 123 rev A to part number 123 rev B, they can transfer the parts to the Work Order and identify the serial numbers transferred.  Parts may also be changed to a new part number:  Part Number 123 rev A can be placed into a re-work Work Order for part number 234 rev C.  The only condition is that the quantity and number of serial numbers must match.  Once the record is saved a line shortage for the rework work order will be created and serialized parts will be issued to the "Rework" work order and the old part number will be removed from FGI at the time the new part number is moved into WIP.  See example below:

 

 

Serialized Inventory Parts (910-9000 Rev. A1) in FGI

 

 

Create a Rework Work Order using a different Part Number (910-12000 Rev. B)

 

 

Enter the Work Order Serial Number Control Module and enter in the SN's you want to rework, if the SN you entered is found in other locations a screen will appear displaying all the PN's that have this SN in FGI and user can select which PN they want to pull this SN from

 

 

Once user has assigned all the SN's to this WO, they should depress the Save button 

 

  

 

Now user can go to the Kitting Module and release the kit.  The Make Parts #910-9000 Rev. A1) have already been issued to the Kit. 

 

 

And Removed from FGI for the Old PN (#910-9000 Rev. A1) 

 

 

 

 

 

Enter Production/Work Order Management/Work Order Serial Number Control Module

The Serial Number Setup Screen will appear.  Depress the Report action button and the following report menu will appear:

Decide upon the Output.Select Screen, Printer, XL File, TXT File, or PDF.  Select the Detail Report you want by highlighting either By Part Number / Work Order or By Serial Number.  Depress the Options Tab.  The following screen will appear:

Depress the down arrow at the left of the Part Number field.  A list of Part Numbers will appear.  Select the appropriate Part Number.  A list of all Work Orders pertaining to that Part number will display.  Highlight the Work Order of interest and depress the > button.  Depress the OK button.  If you want all of the Work orders, depress the >> button.  The leading zero's for SN's will be removed from Report.

The following report will print:

Enter Production/Work Order Management/Serial Number Status & History Module   After activation, "Serial Number Setup" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.

The following screen will appear:

Enter a serial number in the Serial number box (red box) and all the following information will appear;

Serial Number Status & History Fields and Definitions

Transfer History Fields & Definitions

Defect History Fields & Definitions

 Late Tab fields and Definitions

The Backlog Tab - displays a list of Work Orders with a status of "Open" that have been scheduled and still have a balance remaining

 

Backlog Tab fields and definitions 

 

This button gives the user the capability to manually reschedule all currently scheduled jobs to maintain WC due out dates within the Dynamic Scheduling module.

 

The user may sort by Work Order, product Number, Build Quantity, Complete, Back Order or Completion Date by clicking on the header buttons.

Find a Scheduled Work Order, depress the Edit Button, and enter your password.  

Depress the Exit button.

From there, the user can enter the Dynamic Production Scheduling module and re-schedule Work Orders.

There is also the opportunity to graphically view the Capacity Critical Path.

Enter Production/Capacity & Scheduling/Production Capacity Setup

 

 

The way the system calculates the hours and volume is:

 

Wednesday:  has both the Day Shift and the Swing Shift and is associated with both Activity-1 and Activity-5.

Hours:   (4.28*2 + 7.5*1) + (4.28*2 + 7.5*2) = 39.633   or  (Day Shift hours x Resource Assignment for Activity-1) (Print Screen 1)  plus  (Swing Shift hours x Resource Assignment for Activity-1) (Print Screen 2) = 16.06   plus   (Day Shift hours x Resource Assignment for Activity-5) (Print Screen 3)  plus  (Swing Shift hours x Resource Assignment for Activity-5) (Print Screen 4)  =  23.56  for a total of  39.633 

Volume:  (4.28*2 + 7.5*1)*12  +  (4.28*2 + 7.5*2)*5 =  310.633   or   (Day Shift hours x Resource Assignment for Activity-1) (Print Screen 1)  plus  (Swing Shift hours x Resource Assignment for Activity-1) (Print Screen 2)  x  Activity-1 Standard Rate  (12.00)  =  192.72   plus   (Day Shift hours x Resource Assignment for Activity-5) (Print Screen 3)  plus  (Swing Shift hours x Resource Assignment for Activity-5 (Print Screen 4) x Activity -5 Standard Rate  (5.00) =  117.80  for a total of   310.52

 

 

Thursday:  The same as Wednesday

Friday:  The same as Wednesday

Saturday:  The same as Monday

The Time Card module has two functions:  1) to enter the employee coming in at the start and end of the shift, and 2) to track time spent by each employee on each Work Order (Job), by date and time.  This information will forward to the Time and Attendance module. 

The Time & Attendance module captures information from the Time Card module regarding the worker logging in for the shift and/or logging into a job (Work Order).  The user or his/her supervisor may also add additional information into Time Log Management, regarding time off for vacation, jury duty, etc.  Several printed reports are available.  The information regarding time spent on each job (Work Order) forwards to the Job Costing Module.

If you want to keep track of times worked against a Work order you need to use the Time Card and log in/out of a work order.  This will allow you to track hours spent on a specific Work order/job.  At the same time the Time & Attendance module will allow a user to be logged in to a different department/workcenter.

If you are looking to use the Time & Attendance module to provide the hours for your payroll system we are going to suggest that regardless of the Work orders the user might be logged into, you will still have to have a record created for the hours worked by that employee for that day per Department and/or Workcenter, by having the employee log into the Time card at the beginning of the shift and logging out at the end of the shift, then run the "Employee Time Card Summary" report.  This should give you the information for your payroll. 

You cannot use a combination of WO log ins and Time Card log ins.

Field & Definitions:

Employee ID	The workers Identification as entered in Security Setup .
Last Name	The Last name of the worker.
From Date	The first date to be included in the Time Log.
To Date	The through date to be viewed for the Time Log.
Date In	The Date the employee logged in for the shift or for the job.
Time In	The time the employee logged in for the shift or into the job.
Date Out	The date the employee logged out of the shift or out of the job.
Time Out	The time the employee logged out of the shift or out of the job.
Hours	The difference between Time In and Time Out.
H	A check in this box indicates that this is a Holiday
Type	The type of time logged as defined by the Time & Attendance Types in System Set up.
Work Center/Dept	The Work Center or Department the employee is assigned to in Security Setup .
WO Number	The Work Order number logged into in the Time Card module.
O/T Hours	This is hours worked outside of normal hours based on the user setup.  (This can be hours in a shift, hours in a day, or hours in the week).
Total RT for Jobs	The total Regular time for Type (W) only
Total RT for Other	The total Regular time of all other types than (W) or (T)
Total RT for Time Card	Total Regular time for (T)
Total Regular Hours	Grand Total Regular hours for all Types
Total OT for Jobs	The total Overtime for Type (W) only
Total OT for Others	The total Overtime of all other types than (W) or (T)
Total OT for Time Card	Total Overtime time for (T)
Total Over Time	Grand Total Overtime hours for all Types
	Depress the button to re-calculate hours after editing, or adding a record
	Depress this button to update Holidays.  This will add the holiday hours to each employees records according to their shift setup.  Note:  The Holiday must be setup in the Admin/Production Calendar.
	Depress this button to Update the Date Range.  This refreshes the dates displayed in the lower grid according to the from and to date fields.

To obtain the Time & Attendance reports, depress the Reports button.The following screen will appear: Select the output you desire by clicking on the radial.Choose from Screen, Printer, XL File, TXT File, or PDF. Highlight the report. Depress the option tab. Note that the Time columns is expressed in hours and fractions of hours and not in hours and minutes.

Employee Time Card Detail

Enter the desired date range.  Depress the radial for either Work Center or Department. Depress on the Work Center down arrow and select the appropriate Work Center. Highlight the desired employee and then depress the > button.  If you want all employees, depress the >> button. Depress the OK button. This report is designed to calculate the total hours user is logged into system, regardless if it is linked to a Work Order or not.

The following is printed:

Employee Time Card Summary

Enter the desired date range.  Depress the OK button. This report is designed to calculate the total hours user is logged into system, regardless if it is linked to a Work Order or not.

The following is printed:

Employee Work Order and Work Center Activity

Enter the desired date range.  Highlight the desired employee and then depress the > button.  If you want all employees, depress the >> button. Depress the OK button. This report is designed for calculating user logging in/out of all jobs within the desired date range.

The following is printed:

Work Order Time Log Activity

Select to View Work Order Time Log Activity for a Single Work order, then enter the Work Order in the box and depress the OK button, or Select to View the Work Order List and highlight the desired Work order number and then depress the > button.  If you want all Work orders, depress the >> button. Depress the OK button. This report is designed for calculating all activity for the desired Work Order number.     NOTE:  If the user has reached the maximum number for the mover list, a system error may occur when the user selects recently created WO's.  They MUST then use the Single Work Order selection and enter the Work Order.

The following is printed:

The worker shift must be assigned to a user within this screen for the Time Card and Attendance and Time Card modules.    

Field Definitions of Users Work Shift Setup