Optional Prerequisites:

The STATISTICAL QUALITY CONTROL (SQC) Module ~ Defect Entry screen is used to record defects and inspection results during the movement of product through the production Work In Process (WIP). The user has a choice of entering data in a batch mode or in an in-line mode See Article #1769 for further detail.   Batch mode is the entry of data accumulated during an inspection period, and is data entry only (does NOT transfer product from one work center to another).  In-line mode is where inspection is done at the end of a work center or activity, and the product is to be moved to another work center based on the results of the inspection. In-line inspection would require inspection of 100% of the product, in order to move the product from one step to another. It also requires the use of a ManEx workstation at the inspection station, so the data may be entered real-time.

Defect entry is based on having a standard nomenclature for the defects in the Quality Defect Codes setup, so that the users do not have the option of creative descriptions. The defects in the setup may be ascribed to specific work centers, to minimize the number of defects that an inspector (or data entry person) has to view to find the appropriate defect.

Defect information may be recorded by work order and/or by serial number. Defects may be associated with a specific “location” (reference designator) on the assembly, providing the user has entered reference designators for the assembly in its Bill of Material .  

If the user chooses to enter reference designator locations for the defects, and has entered reference designators on the Bill of Materials, then ManEx will prompt the user to select the manufacturer for the part used at the location, as well as automatically enter the internal part number at that location.

There is also provision for tracking the diagnostics and repair of each defect and assembly. The user may view the history of the assembly’s movement through production, and all of the defects associated with each assembly.

Quality Inspection Entry Screen Field Definitions

Defect Information Screen Field Defintions

All data must be Entered in the Quality Inspection Entry and Defect Information screens, with in the Shop Floor Tracking Module.

Entering a Defect Code Entry to a Work Order

For closed Work Orders:  In the Security module, there is an option which must be checked per user for the “Defect Code Entry”. Once the Security right has been entered, the user may edit a “closed” Work Order.

 

The first screen presented to the user depends on whether or not in the system setup/Quality Defect Codes, the user has selected to enter defect information in BATCH or IN-LINE mode. If the user has selected IN-LINE in the setup, then only the IN-LINE screen will be displayed. Otherwise, the user will be presented with the batch screen, and the option to enter IN-LINE data. 

Batch mode is used for entering data previously recorded during inspection of the product. When the user chooses to enter defect data in “In-Line” mode with the serial number, the user won’t be able to enter “lot quantity”, “inspection quantity” or “failed quantity”.These fields are all defaulted in when the user goes into the “Defects Information” tab.  However, if the user enters defect data in “batch” mode without the serial number, then the user will be able to enter “lot quantity”, “inspection quantity” and “failed quantity”.

If the user wishes to 100% inspect material, and directly move the passed material to the next routing work center, then the In-Line Inspection mode may be used.

The user has the ability to limit some workstations (specific PCs) (which is defined in the Security Module) to be able to only transfer material “FROM” a certain Work Center.  When the user transfers material from a Work Center (A Serialized part Number Only) in the Defect Code Entry In-Line Mode, the system will check to see if the serial number is currently in the Work Center.  If not, a special supervisor’s password is required to transfer the serial number FROM a different Work Center.  After the supervisor’s password is entered, the system will use the new Work Center to be the default FROM Work Center until the user closes the screen.  The next time the user opens the screen, the default FROM Work Center will be changed back to the one defined in the Security Module. 

Enter Production/Shop Floor Tracking by Work Order Module Find a Work Order in SFT Module,

The following screen will appear:

Depress the "Inspection" button located at the top of the screen.

The following screen will appear:

Entering Quality Inspection Data

There are two different ways to enter the Inspection Data:  Batch Mode or In-Line Mode

Batch Mode

The first information tab records information about the work order. This includes lot size, failures, inspection quality, date, etc. 

Depress the Add action button.  Enter the password of the Employee that has inspected the product.  

When the user first brings up the Defect Entry program, and before entering or editing data, they have the option to check or uncheck the “Skip Serial No. Field”. Once the data entry process is begun, the option is cleared until the user exits the defect entry form and re-enters it.

Adding Work Order Defect Information Without Serial Number Tracking 

Enter the Work Order number, choose the Inspection Work Center from the pulldown, enter Lot Size inspected, Inspected Qty, and Failed Qty.

The Date, Time, Pass Qty, and Yeild % will default in.  The date and time may be changed if needed.

The user may enter estimated rework time, if desired.

Depress the Defects Information tab and the following screen will appear:

The user may then enter a defect code by manually typing in the code, or by scanning a bar-code menu, or by double clicking on the field to review a list of defect codes.

The list displayed will depend on which view is selected (in upper right hand corner of screen).  If Work Center Defects is chosen, only those defects associated with the work center (as established in the system setup/Quality Defect Codes) will be displayed. If All Defects is chosen, then every defect entered in the system setup/Quality Defect Codes will be displayed.

The user may select one or more defects from the list by holding down the Control Key while clicking on the defects to be selected.

After completing the selection of the defects involved with the current inspection, clicking on the OK button loads the selected defects into the defect information screen.

Although ManEx will enter a Charge To Work Center code based on the work center entered or the location of the part, the user may modify the originating work center by clicking on the field and selecting another work center from the list.

The user may (optionally) then enter in the location (reference designator) where the defect was observed.

The user then must select an Employee from the pull down.  The employee's being displayed in the pull down are only the employee's that are assigned to work centers (in the Security module) that are the same work centers listed in the Shop Floor Tracking by Work Order module and is sorted by the Employee User ID Number.  

 

 

 

The system will check the BOM to be sure that the location entered here matches locations entered on the Bill of Materials. 

When a valid location is entered, then system searches the Bill of Material to find manufacturers approved for the product, and displays a list of the approved manufacturers for the user to identify which manufacturer was associated with the defect observed. The user double-clicks on the manufacturer's name for the defective part, and the manufacturers name is placed in the defect information screen.

ManEx defaults the number of defects to one item, but the user may overwrite the quantity with an observed quantity greater than one.

The user may also enter a brief comment about the defect, for future reference.

The completed screen should appear as follows:

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

If you depress the Save record action button, the following message will appear:

If you want to add another defect record for the same user "ONE" then depress YES, if you want to add a defect record for a different user (Example user "TWO"), then you must depress NO.  Depress the Add record action button and enter user "TWO"s password and continue to enter the defect information.

When the user has completed the defect information, they may click on the Test & Repair tab, to enter more information about the part.

NOTE:  The Test & Repair is actually a separate OPTIONAL module, but has been included into the Defect Entry screen for ease of use for the operators.  For further detail about this module see Article #3291..

Adding Work Order Defect Information With Serial Number Tracking 

 Enter the Defect Entry screen. Depress the Add Record action button.  Un-check the "Skip Serial No Field" 

If the user is tracking serial numbers, then the first field to be entered (or bar-code scanned) is the serial number of the product being inspected. (Not the Work Order number).

Type in the serial number. When the serial number has been entered, ManEx will complete the work order and product information. ManEx will also enter the current work center location of the serial number supplied.

The user now has the option of continuing to scan (or type) serial numbers, and log the defect information for each one later, or enter a serial number then the defects for that serial number, enter the next serial number, then the defects for the second serial number, etc. When multiple serial numbers have been entered, the data will refer to the serial number that is highlighted in the Serial Number list.

ManEx will enter in the lot size according to the quantity of serial numbers showing in the serial number list.

The next field, “NPF” is provided for the user to record when observing the product and finding that there is “No Problem Found”. If the serial number had previously been rejected, and analysis of the product yield no further problem, either with cosmetics or function, then the user may change this number to 1, meaning the first time it was inspected or tested, no problem was found. If the product serial number is subsequently rejected again, and a second inspection finds no problem, the number may be incremented to a “2”. This will alert users to repeated rejections of a product serial number, one or more times with no discernable defects.

If the number of times that a part has experienced an NPF exceeds that established in the system setup/Quality Defect Codes the user will receive the displayed warning message and will allow you to proceed on with the Inspection.  This is just a notification that the board has passed the maximum NPF cycle. 

Entering Defect Information

This screen operates as described under Entering Defect Information without serial numbers, except that the user must enter data for each serial number recorded. The serial number may be chosen by highlighting the serial number in the serial number box on the first screen, or in the defects information screen, by pressing the down arrow button next to the serial number field and selecting a serial number.

Defect information is entered in the same fashion as described above, except that the user should remember that the data being entered is for one part at a time, by serial number of the part.

The other difference in using serial number defect tracking is that on the Test & Repair screen, the user may view the Serial Number History tab. This view will display both the transfer history of the serial number through the work centers, and the history of defects associated with the serial number of the product.

(Note: if you are entering Defect information and not using the Serial No, then this screen will remain blank)

The user completes the defect entry for the first defect code (The location, quantity of defects observed, etc.). The process is repeated for each defect observed, storing the location and serial number to be analyzed at a later time.

At the conclusion of defect entries for the lot, the Save action button is pressed to retain the data.  If the user elects to ignore all data entered in this session, the Abandon  changes action button may be clicked to void any entries. Notice that ManEx computes the total number of defects observed for the defect code and displays the number next to the defect code. 

Entering Defect Information Without Serial Number Validation

The “Enter Serial Number without Vailidation” option will only be enabled if the user skips the regular Serial number entry, and if the Work Order Product has not been serialized within the ManEx system.

This feature has been added to allow the users the ability to inspect Serial Numbers that do not actually exist within the ManEx system. (for example serial number created outside of ManEx, by customer or other software, etc. . .)  If the user checks the “Enter serial number without validation” then ManEx does not validate when the users enters the Serial Number.  The system just records the entry for later SQC analysis purpose.  (note: if the work order is serialized, then the user can NOT use this feature).

Enter the Defect Entry screen. Depress the Add Record action button.  Select “Enter Serial Number without Validation. ”

Enter the Work Order number.

Then enter in the desired Custom Serial Numbers. The remaining process will then be the same as listed above.

In order to have the "DPMO by Employee" report create valid data, the user must be sure to enter the opportunities for defects (PPM) in the Work Order Traveler Setup and the employee must inspect the board and be assigned to the defects.  The "DPMO by Employee" report only gathers data if BOTH "Inspected By" and "Emp" are the same user, and the PPM is setup.   See Article #3156  for further detail on DPMO.   The following steps need to be followed to collect and track defects per employee. 

All data must be Entered in the Quality Inspection Entry and Defect Information screens, with in the Shop Floor Tracking Module.

Entering a Defect Code Entry to a Work Order for the "DPMO by Employee" report

Enter Production/Shop Floor Tracking by Work Order Module Find a Work Order in SFT Module.

The following screen will appear:

Depress the "Inspection" button located at the top of the screen.

The following screen will appear:

Entering Quality Inspection Data

The first information tab records information about the work order. This includes lot size, failures, inspection quality, date, etc. 

Depress the Add action button.  Enter the password of the Employee that has inspected the product and will be assigned to the defects.  Example:  If user "ONE" is going to be assigned to the defect(s) then you must enter user "ONE"'s password. 

Check the Skip Serial No. Field (if not applicable).

Enter the Work Order number, choose the Inspection Work Center from the pulldown, enter Lot Size inspected, Inspected Qty, and Failed Qty.

The Date, Time, Pass Qty, and Yeild % will default in.

Depress the Defects Information tab and the following screen will appear:

The user may then enter a defect code by manually typing in the code, or by scanning a bar-code menu, or by double clicking on the field to review a list of defect codes.

The list displayed will depend on which view is selected. If Work Center Defects is chosen, only those defects associated with the work center (as established in the Quality Defect Codes setup) will be displayed. If All Defects is chosen, then every defect entered in the Quality Defect Codes  setup will be displayed.

The user may select one or more defects from the list by holding down the Control Key while clicking on the defects to be selected.

After completing the selection of the defects involved with the current inspection, clicking on the OK button loads the selected defects into the defect information screen.

Although Manex will enter a Charge To Work Center code based on the work center entered or the location of the part, the user may modify the originating work center by clicking on the field and selecting another work center from the list.

The user may (optionally) then enter in the location (reference designator) where the defect was observed.

The user then must choose the Emp from the pull down, which would be "ONE", because it needs to be the same user that has been entered in the "Inspected By".  The user is allowed to enter other user's name on Defect detail page in the "Emp" column.  But when the "DPMO by Employee" report is run, it will not display the records assigned to the different users.  

The system will check the BOM to be sure that the location entered here matches locations entered on the Bill of Materials. 

When a valid location is entered, then system searches the Bill of Material to find manufacturers approved for the product, and displays a list of the approved manufacturers for the user to identify which manufacturer was associated with the defect observed. The user double-clicks on the manufacturer's name for the defective part, and the manufacturers name is placed in the defect information screen.

Manex defaults the number of defects to one item, but the user may overwrite the quantity with an observed quantity greater than one.

The user may also enter a brief comment about the defect, for future reference.

The completed screen should appear as follows:

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

If you depress the Save record action button, the following message will appear:

If you want to add another defect record for the same user "ONE" then depress YES, if you want to add a defect record for a different user (Example user "TWO"), then you must depress NO.  Depress the Add record action button and enter user "TWO"s password and continue to enter the defect information.

When the user has completed the defect information, he/she may review the "DPMO by Employee" report Article #815, or may click on the Test & Repair page, to enter more information about the part.

The Test & Repair is actually a separate OPTIONAL module, but has been included into the Defect Entry screen for ease of use for the operators.  Please see the Test & Repair Management (T&R) article for more information.

Enter Quality/Engineering/Statistical Quality Control (SQC) Module

The following screen will be displayed:

Template Selection Setup

This is the first screen to be used in the module. In this screen, STATISTICAL QUALITY CONTROL graphics are created by selecting parameters to be considered in the graph.

This screen operates differently than all other ManEx screens. When bringing up the SQC module, the user is first presented with a template screen from which to choose parameters to be included in the information displayed. 

When the user enters the system, he/she may select how they want to start the process of selection.  Click on the Customer, Part Number or Work Order radial.

Clicking on the Customer radial will bring up the following selection screen:  Select either Customer List or All Customers.

Selecting by Customer List will bring up the following selection screen: (If the user selects by All Customers, the same screen will appear except  All available Customers will be listed within the Customer section) Type the desired customer into the red box or highlight and double click.

The following screen will appear:

If the start is from Part Number, the following selection will appear:

If the user selects Product Number List, the following list will appear: (If the user selects All Products, the same screen will be displayed except all products will be listed in the part number section) Type the Part Number into the red box or highlight and double click.

If the user starts with the Work Order start, the following selection will appear:

If the user selects the Work Order List option, the following list of Work Orders will appear:  (If the user selects All Work Orders the same screen will be displayed except all work orders will be listed in the Work Order section) Select between Open or All. Type the Work Order Number into the red box or highlight and double click.

The following screen will appear:

	In the Work Order section, choose from All, One or Some.  If you’ve selected one, highlight the desired work order.  If you want more than one, depress the Ctrl key and click on the ones desired.
	In the Work Center section, choose from All, One or Some.  If you’ve selected one, highlight the desired work center.  If you want more than one, depress the Ctrl key and click on the ones desired.
	Make the same selection in the Defect List section.  If you want all defects displaying as per the System Setup, check the Defect List box.
	To make a new selection, depress the New Selection button.

Template Detail Screen

Pressing on the Template Detail tab brings up the following screen:

Enter the Date Range, From and To.  Mark the Radial for the view by Daily, Weekly, Monthly, or Yearly.

Mark the radial for the User Defined Limits for DPMO chart:  Lower Limit, Central Line, Upper Limit or Reset.  Indicate Central Line amount in box.

Mark the radial for the User Defined Limits for pChart:   Lower Limit, Central Line, Upper Limit or Reset.  Indicate Central Line amount in box.

To Save this template for future use go back to the Template Selection/Setup tab enter in a name and depress the Save button. 

 

 

The Template will be saved in the Viewing Template field for future use.

 

Enter Quality/Engineering/Statistical Quality Control (SQC) Module

The following screen will be displayed:

Template Selection Setup

This is the first screen to be used in the module. In this screen, STATISTICAL QUALITY CONTROL graphics are created by selecting parameters to be considered in the graph.

This screen operates differently than all other ManEx screens. When bringing up the SQC module, the user is first presented with a template screen from which to choose parameters to be included in the information displayed. 

When the user enters the system, he/she may select how they want to start the process of selection.  Click on the Customer, Part Number or Work Order radial.

Clicking on the Customer radial will bring up the following selection screen:  Select either Customer List or All Customers.

Selecting by Customer List will bring up the following selection screen: (If the user selects by All Customers, the same screen will appear except  All available Customers will be listed within the Customer section) Type the desired customer into the red box or highlight and double click.

The following screen will appear:

If the start is from Part Number, the following selection will appear:

If the user selects Product Number List, the following list will appear: (If the user selects All Products, the same screen will be displayed except all products will be listed in the part number section) Type the Part Number into the red box or highlight and double click.

If the user starts with the Work Order start, the following selection will appear:

If the user selects the Work Order List option, the following list of Work Orders will appear:  (If the user selects All Work Orders the same screen will be displayed except all work orders will be listed in the Work Order section) Select between Open or All. Type the Work Order Number into the red box or highlight and double click.

The following screen will appear:

	In the Work Order section, choose from All, One or Some.  If you’ve selected one, highlight the desired work order.  If you want more than one, depress the Ctrl key and click on the ones desired.
	In the Work Center section, choose from All, One or Some.  If you’ve selected one, highlight the desired work center.  If you want more than one, depress the Ctrl key and click on the ones desired.
	Make the same selection in the Defect List section.  If you want all defects displaying as per the System Setup, check the Defect List box.
	To make a new selection, depress the New Selection button.

Template Detail Screen

Pressing on the Template Detail tab brings up the following screen:

Enter the Date Range, From and To.  Mark the Radial for the view by Daily, Weekly, Monthly, or Yearly.

Mark the radial for the User Defined Limits for DPMO chart:  Lower Limit, Central Line, Upper Limit or Reset.  Indicate Central Line amount in box.

Mark the radial for the User Defined Limits for pChart:   Lower Limit, Central Line, Upper Limit or Reset.  Indicate Central Line amount in box.

Indicate the user defined goal for the Yield Chart.

View Chart Screen/Graphs

Pressing on the View Chart brings up the Graphics Display Window.

Defect Pie Chart -  The results being displayed in the Defect Pie Chart are from WO #242 for a build of 500.  Qty of 5 with Wrong Part (Displayed in the Blue) 62.5%  and Qty of 3 with Leads Bent (Displayed in Green)  37.5%.  Total qty failed 8.

 

 

 

 

DPMO (Defects Per Million Opportunities) Chart   (Which means the number of things wrong observed in the inspection of a part, or board assembly).   The results being displayed in the DPMO Chart are from WO #242 for a build of 500.   DPMO Example below = 8(Total qty failed)* 1000000/100*500 (Qty Inspected) = 160

Defects Per Million Opportunities.  There are several ways to setup the opportunities (which means the number of possible defects that can occur on a product),  but it is up to each company to make that decision.  For Example: Some may say that a resistor with two leads that are not properly soldered is counted as two defects and some may only count it as one defect, since it is one part that was assembled incorrectly.   The opportunity or the standard opportunity is entered in the Work Order Traveler Setup module.  The field is called PPM = Parts per million. 

The DPMO chart uses the PPM as a reference to measure the actual failures against the total inspected quantity.

See Article #3156  for further detail on DPMO. 

The formula for calculating DPMO chart is as follows:

Example (2+3+3) = SUM of defect quantities (8) * opportunities or PPM (1,000,000) (divided by) Qty Inspected (500) (divided by) parts per unit (100) = 160

Daily, Weekly, Monthly, Yearly

On the Y axes the graph shows number of defects per million

One the X axes day or week or month or year

This graph collects defect information for the selected work centers and work orders in the selected date range. The user also has to select if the information will be grouped by day, week, month, or year.

The selected group will be your X coordinates on the graph.

The Y coordinates will be calculated as sum of the defect quantities *opportunities or PPM divided by total Qty inspected (divided by) parts per unit (qty was entered in the routing module) grouped by X coordinate unit (Daily, weekly, monthly, yearly).

This is a data line there is three more control lines displayed on the graph:

Central control line:

Upper control line:

Lower control line

All three lines could be user define lines.

If the lines are not user define lines they calculated as following

Central Line

lnCentralLine=lnTotalDef/lnTotalComp, where lnTotalDef is sum of all defect quantities * 1000000 and lnTotalComp is sum of inspected quantities*Parts Per Unit (entered in the routing module)

At this time system will decide if it can use average group size or not. If the size group varies more tan 15% the system will use variance Upper and Lowercontrol limit.   If average group size could be used the average group size gets calculated by taking lnAvrgSubgrSize=lnTotalComp divided by number of groups and rounded to the nearest integer.

Calculation for the Upper Control Line

LnUpperLine=ROUND(((3*(SQRT(lnCentrLine*(1000000-lnCentrLine))))/SQRT(lnAvrgSubgrSize)),3)

Calculation for the Lower Control Line

lnLowerLine = ROUND(lnCentrLine -((3*(SQRT(lnCentrLine*(1000000-lnCentrLine))))/SQRT(lnAvrgSubgrSize)),3)

Defects Distribution Chart - The results being displayed in the pChart are from all Work Orders, Work Centers, and all defects from 062706 thru 072706 (1 month)  

Yield Chart -  "Yield" =  Total number of units handled correctly through the process step(s). This is usually measured in a percentage.  The results being displayed in the "Yeild Chart" is the ratio of summed inspected qty and summed passed qty, grouped by date (user can select WO number, defect code to be filtered).  The results below are from all Work Orders, Work Centers, and all defects from 062706 thru 072706 (1 month).  

 

1^st Pass Yield Chart  The results being displayed are from all Work Orders, Work Centers, and all defects from 062706 thru 072706 (1 month).  

1st Pass Yield chart in the SQC module is designed only when the serial number is used for the work order.  The system uses the serial number to determine how many serial numbers passed without failure/defects within a work order.  1st Pass Yield chart will be blank if there are no product tracked by serial number within the production floor

 

 

 

To enter a new title, depress the Graph Title button. The following will be displayed:

Enter in the new desired Graph Title. Depress the Exit button, and the graph title will be updated.

3D/2D - This is if you want to view the 1st Yield Chart in 3D

The Corrective Action Request (CAR) module is used to record and track to the conclusion of all corrective action requests.

The user may establish his/her own type(s) of corrective actions in the system setup. Examples of types of corrective actions may be Supplier, Customer, Production, Administration, etc. In addition to classifying corrective actions by type, the user may also establish number types for the corrective action. Examples of number types might be RMA, DMR, Internal, etc.

The user enters information relating to each CAR including ISO reference, Quality Manual Descriptions, Customer/Supplier information and/or Work Center/Department involved.

There is provision for text entry of the Description of Condition, the Apparent Cause, and the Actual Cause, along with provision to enter a graphics image.

In the Corrective Action section, there is provision to enter Corrective Action Taken, as well as information for Follow Up & Review.

In the Main screen, a list of all open corrective actions is displayed, and may be sorted by Due Date, New Due Date (if revised), CAR number or CAR Type.  There is provision to enter the name of the CAR Coordinator, and include a list of team members and their percent completion of the task. There is also a place for users to enter the date and name of the team member who verified the problem; the date and name of the team member who granted the final approval of the CAR; the date and name of the team member who followed up on the CAR; and the date and name of the team member who closed the CAR.

Status of Team Progress section

Graphics Display Window	If some work has been completed by the team and registered in the Open List tab, a graph displaying the percentage of completion by each team member will display.
	Depress this button to change graph view to 3D or back to 2D.
	This button will bring up a list of users who can be assigned to the CAR team.  In order for the user to be displayed on this list they must have Edit or Add rights to the CAR module within the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access. .

 

 

Enter Quality/Engineer/Corrective Action Request(CAR/Corrective Action Request (CAR)

The following screen will appear:

 

Depress the Find Record action button.

 

The following selections will be displayed:

Find by CAR Number

Depressing the Find by CAR Number button, will display the following listing of all of the Open CAR Numbers available. Type the CAR Number into the red box or highlight and Double Click to select.

Find by CAR Problem Type

Selecting the Find by CAR Problem Type option, will display the following listing of Open records. Type the problem type into the red box or highlight and double click.
The following selection screen will appear: Type the CAR Number into the red box or highlight the selection and double click.

Find by Closed CAR Number

 

Selecting the find by Closed CAR number, will display the following listing of Closed CAR’s. Type the CAR Number into the red box or highlight the selection and double click.

 

Find by Closed CAR Problem Type

 

Selecting the Find by Closed CAR Problem Type, will display the following listing: Type the CAR problem type into the red box or highlight the selection and double click.
A list of all closed CAR's for that problem will appear: Type the CAR number into the red box or highlight and double click.

 

Enter Quality/Engineering/Corrective Action Request(CAR)/Corrective Action Request (CAR)

 

 Enter the CAR Description. 

Depress on the down arrow to select the CAR Type:

If you select Work Center/Dept, a further selection screen will appear. Select one Work Center or Department.  Upon selection, the name of that Work Center will appear in the Work Center/Department box.

If you selected Customer or Supplier from the above as the CAR Type, a further selection screen will appear:   The Supplier List will be sorted by Supplier Number.  The Customer List will be sorted by Customer Name in Alphabetical Order.   The name of the Customer or Supplier will appear in the Customer/Supplier Name box.

Depress on the down arrow to select whether the problem is Major or Minor.

Depress the down arrow next to the Number Type field.  The following list will appear:   Select the type applicable to the CAR.

 

Depress the Assign button and a list of employees will appear that have Add or Edit access rights to the CAR module setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access. Make the selection for the Team Members. Depress the OK  button.

 

Depress the Edit button and the Approval lists will be enabled:

Enter Quality/Engineering/Corrective Action Request (CAR)/CAR Follow Up List After activation, "Corrective Action Request" (CAR) 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 be displayed:

 

Displayed will be all of the Correction Action Requests upon which follow up action has taken place.

The fields displayed are as follows:

Depressing the Reports icon, the system will then display the following dialog box.     Select the desired Printer. Depress the OK button and the report will be sent directly to the selected printer.

Enter Quality/Engineering/Corrective Action Request (CAR)/CAR Assignment List After activation, "Corrective Action Request" (CAR) 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 be displayed:

 

This screen will display all of the Corrective Action Request for which a team member has been assigned, and has not been completed.

The fields displayed are as follows:

Depressing the Reports icon, the system will then display the following dialog box. Select the desired Printer. Depress the OK button and the report will be sent directly to the selected printer.

Indented Bill of Material: The Top-down breakdown of the structure of a product. In an indented BOM listing, every subassembly and component is indented one level from the assembly or subassembly into which it goes.

Parent and Child Relationships in BOM’s: Each product “parent” has an indented list of “child” components and subassemblies that go into it. Each child item is indented under its parent and may in turn have child components indented under it.

Accepted Manufacturer List (AML): The AML is the list of manufacturer part numbers entered in the Inventory Control Mgt.- Quantity Info screen. A manufacturer must first be set up in the Inventory Control Mgt./ Part Manufacturer Setup before its approved part number can be added.

Accepted Vendor List (AVL): AVL’s show which manufacturers are approved or qualified for use for a particular customer’s product line or individual product. Only manufacturer part numbers that have been entered in the AML for a particular item can be selected or deleted from the AVL for a customer. A customer’s Approved Vendor List of manufacturers for each internal part is maintained in that customer’s Consigned Inventory record for that part.

Consigned Inventory AVL Record: When a Customer part number is assigned in the Inventory Control Mgt.- Customer Reference screen, a Consigned Inventory Record is generated for that item and customer. The Quantity Info screen for the Consigned Customer part number is where the Customer’s AVL is maintained. Q.Do I have to go into the Inventory Control Management module and assign a customer to the part number? A.Only if the user wants the cross-reference to the customer part number to show for internal parts on the BOM. This field will show up if a BOM Assembly is attached to a specific customer.

Anti-AVL: Normally the AVL for each customer applies to all of their product BOM’s. However, if a customer wishes to disqualify a manufacturer from use in one particular BOM, removing a check-mark from the Anti-AVL field may be used to keep the otherwise approved manufacturer from being used on specific BOM’s.

Generic and Manufacturer Preferences: A Generic (Genr) manufacturer means that any manufacturer’s part can be used.Generic is generated by the system as the default manufacturer if no other is specified. If specific manufacturers are listed for a part, preferences for use in an Internal or in a Customer’s product may be entered. Preferences are entered in the Inventory Control Mgt.- Quantity Info screen as 1 for 1^st, 2 for 2^nd, etc. next to the manufacturer.

Functions  

Bills of Material serves many functions in the manufacturing environment. They are central to all manufacturing operations and are used for everything from product specification to quotation document. BOM’s are key to material requirements planning, kit organization, product structure, and configuration control.

Material Requirements Planning (MRP): The BOM is the master plan for building product. An indented BOM from the product top level down to the lowest level component provides the entire material picture for a product. Its quantity and manufacturer preferences are used to kit materials for production to assemble. Its linkage to Item Master Purchase and Production Lead Times and Work Center offsets are used by the MRP to determine which parts to purchase or make and when to provide them. By listing multiple manufacturers and alternate part numbers, the BOM can be used to manage work order shortages.

Kitting by Work Center: Selection of a Work Center for each BOM Line Item causes that item to be kitted with other parts for that Work Center. Grouping of the parts needed for the first Work Center helps determine when to start a work order and eliminates the need for sorting out needed parts at each Work Center. Also if parts are not kitted until needed for later work centers, they need not be purchased or made until closer to the time they are actually needed.

Production Offset: This time difference between the start of the kit for the first Work Center and the kitting for the Work Center where the part is needed is called Production Offset and can be entered for each line item in the BOM. For example, mechanical parts and chassis parts may not be needed until the work order reaches the final assembly work center. By identifying those parts as Final Assembly parts and entering “x” number of days of Production Offset, the parts will not be scheduled for delivery by the MRP nor need they be kitted for “x” days later than the rest of the Work Order. An entry in this field will displace the due date required by the amount of offset established in the BOM. If the user wanted a part or assembly to be ready on the third week of an order that took 4 weeks, then the user would enter a 3 week offset, and the MRP module would suggest ordering the parts three weeks later than otherwise. Please refer to the Material Requirements Planning Management manual.

Engineering Change Control: BOM’s are unique by their revision number and as such are used to control changes to the structure or components in a product. By creating a new Revision level of the BOM with an Effective Date the next day after the Obsolete Date for the old BOM Revision, the user can drive changes in material requirements, kitting and work orders. Or if the new BOM Revision level is to co-exist with the down-rev. Revision, the new BOM is just activated without obsoleting the old BOM. With BOM Revision control, several revisions may exist with different definitions for each. BOM Notes may be used to record Engineering Changes for tracking purposes in the absence of a formal ECO system or documentation.

This is the screen that appears when opening the module. The product number is displayed in the Bill of Material Module screen header as a reference.  The product information will remain on screen while viewing other sections of the BOM module.  BOM Main may be used to view, edit, add or delete a Bill of Material.  BOM Header information is displayed for any item located after a FIND.  If any Line Items have been added to an assembly in the BOM Header, they will be displayed in the Detail Window below.  The lines that are inactive will be highlighted in purple. Selection of a Line Item in the Detail Window will cause the other BOM screens to be populated with default and/or added information for that Line Item. Start with this screen to add a new BOM, edit an existing BOM, add a new Line Item or change detail information for existing Line Items.                

The Header Information fields across the upper half of the screen are populated from the item master and from keyed-in assembly data. The fields in the Body (Detail Window) show information about the components included in the assembly.

BOM Main Field Definitions

Depressing the down arrow will display the history of the BOM components. Current reflects the most recent listing; BOM History will display the history of changes. Selected Date will bring up a selection screen.   Note:  If the effectivity and obsolete dates are used, then it is possible to check the specific parts list at any given data using the BOM history.

Status	The BOM Status:  Active - BOM is Active;  Inactive - BOM is Inactive which will affect Cost Roll up.   NOTE:  Changing the BOM status to Inactive will NOT remove the MRP demands you MUST Inactivate the part number in ICM to remove the MRP demands.  See Article #3430 for further detail. Quote -  This status is in case a BOM is in a quote stage and the user needs a reminder that the quote for this BOM is pending.      This status is for the BOM ONLY, it will NOT change the status of the Inventory part.  The Inventory part status and BOM status can be different.  This is to allow flexibility so the BOM can be inactive and will NOT be displayed in the BOM module, but the part will still be displayed in the inventory listing.   Users will be allowed to change the status on a BOM from Active to Inactive with open SO, WO, etc. and MRP will still show demands.  Users will also still be allowed to Create NEW SO, WO, etc if ONLY the BOM status is Inactive.  Users will NOT be allowed to change the status on the Inventory part from Active to Inactive with open SO, WO, etc.
	When the BOM is made Inactive this field will display the status along with the date and Initials of the user that Inactivated the BOM.
	This allows the user to find part by Reference Designator.  If user starts typing reference designator into the text box it will auto fill the information, when done entering user can press "Enter" or click on the search button next to it and the record pointer in the grid will advance to the part if a match is found.
Customer Name	The name of the customer for whom the user is making the assembly.Select from pull-down list. Add new customers in Customer Information Management. Use Standard Pricing as the customer or leave blank if the assembly is built to stock or has more than one potential customer. This field must match the Customer for any Consigned parts used in the BOM.
Setup Stscp	This box MUST be checked if you wish for the setup scrap qty’s to be included in the Kitting and MRP calculations,  Checking this box along with a Standard Bld qty will tell the system to use Setup Scrap when calculating the standard cost.   Note:  The "Exclude Scrap & Setup Scrap" options within the  Kitting Setup module will overwrite this option.
Standard Bld	The quantity normally built. Entering a quantity in this box will be used when calculating the Standard Cost.  See Article 3040 for information on how this affects the Std Cost.  See Articles #3067 , #3053 , and #3320 for information on how this affects the Configuration Variance.
Last Change	The date and time of the last change to the BOM automatically enters this field.
By	Initials of user that made last change to BOM.
Mgmt Lock	This option is for BOM's that need to be protected, even from those users that have edit capabilities.  Only Supervisors or users with Lock/Unlock rights within the Security/User rights can modify this checkbox.   If locked, all users can access the screen,  but only supervisors or those with Lock/Unlock rights will have the capability to bypass the lock and make changes, while the BOM is still in lock mode.  The reason we do NOT force the user to unlock the BOM before making any changes, is to protect it from anyone else making changes while the  'authorized" user is making their changes.
Lock Date	The date the Managment Lock Box was checked.
By	The initials of the user that check the Managment Lock Box.

COMPONENT INFORMATION (Displayed in the Body (Detail Window)

When the user has displayed component parts on the BOM Main screen, and has highlighted one of the parts, pressing on the Item Detail Tab will display information about

that component part.  The NEXT and PRIOR buttons are activated in the Detail Information Tabs. Clicking on either button will display the details of the next component in the BOM.

The first row of Header information repeats the assembly Product information.

The remaining fields describe Detail information about the component part.

HEADER INFORMATION 

 COMPONENT INFORMATION

DIRECTIVE BUTTON

The following button is displayed on the BOM Item Detail screen:

Pressing the BOM Item Note button will allow the user to create a notation specific to the component shown, in the current BOM.  To enter a note, depress the BOM Item Note button.  Depress the edit button.  Type in the note.  Depress the Save button.  Depress the Exit button.

When the user has displayed component parts on the summary screen, and has highlighted one of the parts, pressing on the AVL & REF Tab will display Part Manufacturer and Reference Designation information about the component part.  The NEXT and PRIOR buttons are activated in the AVL Information Tab. Clicking on either button will display the AVLs of the next component in the BOM.

The first row of Information displays the selected detail part information.The Customer Part Number will be displayed if entered in the Item Master.

The Right Center portion of the screen displays the reference designators assigned to the component. These fields are optional, but must be completed if reference designator information is to be used in the quality defect collection information.  (The ref designators are case sensitive).

The bottom portion of the screen is available to list alternate parts that may be used in the absence of the primary part. However, these alternate parts are not listed on kit lists, and are only displayed on this screen. On the BOM, Manex provides a place for users to identify “Alternate Part” for each part called out in the BOM. However, this is for information and cross reference ONLY and there is no connection with the MRP, Purchasing or Kitting, etc. modules. The concept here is that if the engineers want to include alternate (not preferred, and not on AVL) parts for the possibility that in case purchasing can’t get the original parts called for by MRP, they could look up the alternate part on the BOM, and then order that part. However, to get the part into the kit, they will have to add the alternate part as a line shortage to the Work Order, and also check the “ignore shortage” for the part(s) originally required and short on the Work Order. Then MRP will work as needed, and the kit will show the alternate part as a (line) shortage until filled. Incidentally, creating the line shortage and checking the ignore shortage for the original part will result in an MRP directive (the next time it is run) to buy the alternate (line shortage) part. Please refer to the Material Requirements Planning and the Kitting, Allocating & Shortage Management modules.

AVL & Ref Designator Field Definitions

COMPONENT INFORMATION

AVL INFORMATION

REFERENCE DESIGNATOR INFORMATION

Number	The sequential number assigned to each occurrence of the component on the assembly.
Ref Designator	The assigned location for each occurrence of the part. (The ref designators are case sensitive).
Prefix	A prefix assigned to reference designators for the current component. Is usually a “C” for capacitors, “R” for resistors, etc
Start No	If the user wishes to fill in the reference designators automatically, then the start number will be the beginning number in the sequence of reference designators assigned.
End No	If the user wishes to fill in the reference designators automatically, then the end number will be the last number in the sequence of reference designators assigned.
	Pressing the Calculate button will fill in all reference designators with the prefix plus incremental numbers beginning with the start number entered.
Quantity	The quantity of components used in the assembly.

ALTERNATE PART INFORMATION

These items are the same as previously described.

DIRECTIVE BUTTONS

	Pressing the Add button in the ALTERNATE area will allow the user to add additional item master part numbers as approved alternates.
	Pressing the Delete button in the ALTERNATE area will allow the user to remove item master part numbers as approved alternates.

To enter the Bill of Material Module depress Quality/Engineering/Integrated BOM & AVL

When the screen first opens, the user is limited to only three of the eleven action buttons shown: Find an assembly, run a Report or Exit.  After finding an assembly, the user may page ahead or back through all Make items using the > right arrow or < left arrow button.  Assemblies having Bills of Material will display the components in the Body (Detail Window) below. Selection of one of the components in the window will cause detail information for that item to be displayed if any other BOM screen Tab is selected. Use the Add icon to add components to the BOM of a displayed assembly.  Use Edit to change or add Header information. Use the Delete icon to Delete the entire BOM ONLY (See Deletions section).  Note: Go to the Item Detail screen to delete only one item from the BOM.

Find a Bill of Material

Find an existing BOM screen selection will display: Select the desired search radials by clicking on them. Choose between Active, Inactive or All for the status, (Note:  The status of the BOM may be different than the status of the Inventory Part).  Since you are doing a find for the BOM you would search by the status of the BOM.   Check the "Display Customer Part #..." box to display the Customer Part number for the "Buy" parts if the BOM is linked to a customer.  Selecting this option may slow down the results.  The system will retain the last choice the user makes for this check box until the module has been exited.

If you know the product number, click on the Search by product number radial and then type the part number into the red box and depress the OK button. If the part number entered cannot be found you will receive a message (shown in the screen) asking you if you would like to select Product from the list of Products.

Depress "YES" and a List of Products will be displayed in the bottom section of the screen.  The parts are listed in alphanumeric order, with the Revision, Product ID, Class and Type.  Note:  The status listed on the right of the screen is displaying the status of the Inventory Part not the status of the BOM, which may be different.  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.

Find a BOM by Part Class

If you know the Part Class, click on the Search by part class radial and then type the part class into the red box and depress the OK button.

When the user is searching for an assembly through the part class option, a screen appears listing all of the products within that  class in alphanumeric order. Note:  The status listed on the right of the screen is displaying the status of the Inventory Part not the status of the BOM, which may be different.  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.

Find a BOM by Customer

If you know the Customer, click on the Search by Customer radial and then type the Customer into the red box and depress the OK button.

When the user is searching for an assembly through the Customer option, a screen appears listing all of the product numbers assigned to that customer in alphanumeric order. Note:  The status listed on the right of the screen is displaying the status of the Inventory Part not the status of the BOM, which may be different.  The parts are listed in alphanumeric order, with the Revision, Class and Type. 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.

BOM Search Results

A BOM Header is created by the system when a Make Item is added to the Inventory Control Mgt Item Master and Saved. When the user wishes to create a BOM by adding Line Items to the header, the existing Header is used. The Header identifies the assembly or product and its revision level, shows the status and after creation,  allows Viewing BOM components by Current, All, or Selected Effective Dates.

Depress the Find button. See Article #571 for Find procedures.

 

 

 

 

Depress the Edit button.   Enter your password. The following selection screen will appear: Select BOM Header Information button.

Select status from the drop down menu.  When selecting the status, this status is for the BOM ONLY, it will NOT change the status of the Inventory part.  The Inventory part status and BOM status can be different.  This is to allow flexibility so the BOM can be inactive and will NOT be displayed in the BOM module, but the part will still be displayed in the inventory listing.   User will be allowed to change the status on a BOM from Active to Inactive with open SO, WO, etc. and MRP will still show demands.  User will also still be allowed to Create NEW SO, WO, etc if ONLY the BOM status is Inactive.  Users will NOT be allowed to change the status on the Inventory part from Active to Inactive with open SO, WO, etc.

If there is a Customer associated with this product, select the customer by depressing on the down arrow next to the customer box. A list of customers will appear. Highlight the customer name and double click. Assigning the customer name to the BOM is an option which you can elect to use or not as long as there is no consigned part. If you do not assign an assembly to a customer, this BOM can be used for any customer you want and not limited to a customer. Assigning to a customer is a requirement if you have any consigned part within the BOM. For the sales price, we allow you to add one or more customers in the Price List module and you can determine the quantity breaks and prices by each customer for the same assembly. When they are assigned in the Price List, SO module will show those assemblies only tied to the customer and avoids having to wade through all assemblies. 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.

To enter a BOM Note depress the BOM Note button.  Depress the Edit button. Enter in the note. Depress the Save button. Depress the Exit button.

If you want set up scrap to be considered in Standard Cost calculation, check the Setup Stcrp box.

Bills of Material may be built up using one of three methods:

1. Using the mouse to Drag and Drop
2. Keyboard data entry (Manual Entry)
3. Copying an existing BOM 

1.  Procedure for Drag & Dropping

The Drag and Drop Operation allows the user to select components in the Summary screen of Inventory Control Management and drag the items into the Integrated Bill of Material & AVL Main screen to add them as line items in the BOM.

Use this procedure as an alternative to Manually Adding Line Items to a BOM.

Open the Inventory Control Mgt. Summary screen and use Find to display the desired components.

Size the Inventory Control display by placing the cursor on the far right hand side of the display.  Wait until it turns into an arrow.  Holding the mouse button down, move it to the left until just the following displays:

Open the Integrated Bill of Material & AVL BOM Main screen, position it in the lower right hand corner of the Manex screen. Depress the Edit button and enter your password.

The following selection screen will appear: Choose Drag and Drop.
The following message will appear:

Move the cursor to the Inventory window. Highlight the desired component. Use the left mouse button to select an item in the Inventory Control Management screen. Release the left mouse button. RIGHT click on the mouse button and CONTINUING TO HOLD THE RIGHT MOUSE BUTTON DOWN, move the mouse cursor over to the BOM screen. Release the right mouse button.

Note:  When you drop (release the mouse button), be sure that you have the cursor over the white area,. Drag each component into the BOM in Line Item # sequence.

Enter the quantity of the part per assembly when prompted.  Select the Work Center.

Type in the prefix for the Reference Designator. Type in the Reference Designator Start Number. Depress the Calculate button.

The Number and Reference Designator Fields will fill in.

Depress the Item Detail tab in the BOM module. The following screen will appear:

Review the detail. If you want to make any changes, depress the Edit button while this screen is open. Type in your password. You may change Item Number, Work Center, Quantity, Production Offset days, Used in Kit, and may add Effectivity Date and Obsolete Date. Depress the Save button.

The following selection option will appear:   If you select Internal Part Number, then enter the Part Number into the Red Box.

If you select Consigned Part Number, Select the Customer from the Pull Down list, then enter the Customer PN into the Red Box.

Information regarding the alternate part will display in the bottom section, as displayed below:

Depress the Save button.

Procedure for Manually Adding Line Items

Use this procedure as an alternative to Drag and Dropping from the Inventory Summary screen.

Open the Integrated Bill of Material & AVL BOM Main screen and Find desired Header.

To add a component, click on the Add Record button, enter password.

The following screen will appear: Select "Yes" or "No" to Auto Line Item Numbering.

The item detail screen will appear:

 

In the Item Detail screen select Work Center to Kit to (use Material Staging if not known), from the drop down menu:

Then select Source (Make, Buy, Consigned or Phantom), from the drop down menu:   When building a BOM in order to have the Source "CONSIGNED" displayed a Customer MUST be assigned to the BOM.   When building a BOM and you enter the source as a “Phantom”, then when entering the part number that is a “Make/Phantom”, the source changes to a Make” part.   The reason the source field shows at all is to limit the number of part numbers that are available to choose from.   But you can enter any valid part number and the source will change to the source of the part number entered.  So, yes, the source of the sub-assemblies will show as a “Make” part, even though they are actually “Make/Phantom” parts. The details of the BOM will also show they are “Make/Phantoms”.   We allow nested phantoms, of either the “PHANTOM” or the “Make/Phantom” variety.  In kitting, we have the code to blow down through the first level of make/phantoms, so that the parts included in the first sub-assembly level down are listed as kit requirements. We have extended this further so that if there are Make/Phantom parts in the first sub-assembly level, those also break down to the components in the second sub-assembly level.  This process extends as long as there are “Make/Phantoms” in the indented BOM.

Either enter the item number by typing it directly into the Part Number field or select Part Class and Part Type, as illustrated below:

Select the Part Class.
Select the Part Type.
Depress the down arrow next to the Part Number box. A list of all of the inventory parts within the selected Class and Type will appear. Type the Part Number into the Red box or highlight and double click to select. If the item is a Consigned Item, enter either the Customer part number OR the Internal Part number, in the respective fields

If you added an internal part and if there is a matching Customer part number in the Inventory Customer screen, it will automatically appear as soon as the internal inventory part is selected.  Conversely, if you typed in a customer part number, the internal part number information will automatically appear.

Enter the Quantity of the item required for each assembly produced.

(Note: Extra parts for setup or run losses should be added in the Inventory Control Mgt. Item Master Run Scrap % or Setup Scrap Qty. field, not in the Bill of Material.)

Enter the production offset days by toggling on the up and down buttons.

If the component is to be pulled in the kit, leave the Y in the Kit box.If not, remove it.

Enter the effectivity and obsolete dates, if desired.

Depress the AVL & Reference Designator tab

If you want to add alternate parts, depress the AVL and Reference Designator tab. Depress the Add button next to the alternate parts section of the screen.

The following selection option will appear, Select Internal Part Number, enter the part number in the red box.

If you select Consigned Part Number, select a Customer from the pull down list, enter in the Customer Part Number in the Red Box.

Information regarding the alternate part will display in the bottom section, as displayed below.

Once user has completed entering all information for line item number, depress the Save button.

Procedure for Copying from an Existing BOM

Depress the Copy button and enter the user’s password will prompt the user for the existing bill of materials from which to copy the components.

If the BOM being copied from contains references to a customer, and or consigned part numbers, the following message appears:

MANEX will populate the new assembly with all of the part information from the existing assembly, except for parts belonging to a customer. Those items will have to be added manually. The filled in BOM is displayed below:

Depress the Edit button to add the customer name and any other needed changes, in any of the screens.

The Delete button takes on dual meanings.  If the user is in the BOM Main Tab when the button is pushed, the button will delete ALL items on the BOM.   You will be prompted for your password. The following message will appear: 

If there are open work orders for the assembly, then the user is presented with a prompt advising that the bom cannot be deleted while open orders exist, as displayed below: 

If the user is in the Item Detail Information Tab when the button is pushed, the button will delete only the item highlighted.  You will be prompted for your password.  The following message will appear:

Use this procedure to edit Line Item details after entering BOM Header information and Line Item Part Numbers and Quantities per assembly manually, using drag and drop, or copying.

Click on the Item Detail tab.  Depress the Edit button and enter password. 

The Item number, Work Center, Qty, Production Offset, Used in Kit, Effective Date, and Obsolete Date can be edited on this screen. 

The Production Offset would be edited, If an item is to be kitted to a Work Center that will not be reached by the Work Order until X days later, enter X days in the Production Offset to allow kitting to that Center X  days later.  NOTE: This will affect the MRP demands until the kit status has been changed to "KIT IN PROCESS". Once the kit status has been changed to "Kit in Process" the parts now become a kit shortage, and the system will calculate from the WO due date or production lead time and NOT from the production offset.

Enter Effectivity Date for the line item to be used in the BOM.

(Note: Prior to Effectivity Date or after Obsolete Date, the line item will not appear on the Current BOM view nor will it appear on a Pick List to Kit the Assembly.)

Edit the "Used in Kit" by selecting Y (Yes) for Used in Kit unless the item is not to be issued when a kit is pulled. Select P (Phantom) to cause a Make subassembly to be treated as a Phantom when kitted. Select N (No) if the item is provided to the Line by some other means than kitting.  (Note: Chemicals and adhesives are typical not-kitted items that are referenced on the BOM for costing or specification but issued to the production floor on a bulk replenishment basis.)

If you depress the AVL & Reference Designator tab the Ref designators can be edited manually in the table OR Enter the Prefix letter, Start No and End No and click on the Calculate button to auto-number.  Here is where you will also check the approved AVL's and uncheck the AVL's that are NOT approved for this BOM.  NOTE:  If "GENR" is approved on the BOM MRP will consider any inventory for that part even if the AVL is NOT approved on the BOM.  When adding new AVL's to the item master, if you do not want the BOM's automatically updated be sure that the "Disable Automatic BOM AVL update" is Enabled.  See article #1477  for more information.

You may also Add or Delete Alternate Parts by depressing the Add or Delete button near the Alternate Parts to select alternative part numbers for the Line Item currently being edited in the BOM. This table is in the BOM screen because alternate part usage is always dependent upon the application and hence is BOM specific. (Note: Use the Quantity Info screen and AVL window to show alternate manufacturers; the alternate part window is only for items with a different internal part number (such as faster or tighter tolerance parts) that can be used on a temporary deviation when there is no choice.)

Within the Bill of Material module the users have the option to mark each item loaded to the BOM as Used in Kit Y, N or F. 

Y = Yes, this part is used in the Kit and will be considered fro MRP demands and appear within the Kitting module Qty Pick screen.  Once the parts have been issued to the kit  the system will automatically decrement it from inventory upon WO complete. 

N = No, this part is NOT used in the kit, but it will be considered by MRP for demands but will NOT appear in the Kit module Qty Pick screen.  This item will still be displayed on the Kit Pick Worksheet but it will have the “N” next to the item so users will know that it is not used in the kit.  Example:  you would use this option for Documentation.  NOTE:   Keep in mind that this item will be picked by the users on the floor but it will not be relieved from inventory in any way through the Kitting module. Users have to go make and manually adjust the inventory qty’s for this type of item.

MRP includes items with "N" flag in "used in kit" for Purchase Order Actions. The flag does not mean don't buy it, but instead, it means don't kit it. The part is still needed, or it wouldn't be on the BOM. Or the quantity would be zero. This feature is usually used by Users who have bulk stock on the floor, and the assemblers pull the parts out of floor stock.  But there still remains the requirement to get the parts in house so they can be put into floor stock.

F = Floor, this would be used for an item that is not kept in the Stock room but is physically stored out on the Floor in production.  “F” items will also be considered by MRP for demands, but will NOT be displayed on Kit Module Qty Pick Screen or the Shortage report.  This item will still be displayed on the Kit Pick Worksheet but it will have the “F” next to the item to indicate to the users that it is located on the Floor.  NOTE:  Keep in mind that this item will be picked by the users on the floor but it will not be relieved from inventory in any way through the Kitting module.  Users have to go make and manually adjust the inventory qty’s for this type of item.

Within the Bill of Material Module you will see a Setup Scrap check box and a Standard Build field.  If you wish for the setup scrap qty’s to be included in the Kitting and MRP calculations,  Standard Cost Adjustments, etc. . . you need to make sure that the BOM has the Setup Scrp box marked.  Then upon checking this box the system will default in the Standard Build qty to 1 (just because it can not be blank)  It is recommend that you change the Standard Build qty to the desired average build qty for the product (the Standard Build will affect how the system will calculate Standard Cost Adjustments, etc. . . within the system)

To display or print a Report for a BOM, first find the BOM. (See Article #571).

1. To access the reports, depress the Print action button at the top of the screen.  The report screen will appear.

2.  Select the output you desire by selecting one of the output radial selections at the top left of the screen, Screen, Printer, XL File, TXT File, or PDF.

3.  Highlight the report desired and click on the option tab.  (The BOM reports will indicate in the Source column if the item is setup as Make/Buy or Make/Phantom, along with Consigned or Buy).

BILL OF MATERIAL WITH REFERENCE DESIGNATORS

For the BOM with Reference Designators report check if you would like the BOM Notes to be displayed on the report.   Depress the OK button.

The following is printed

BILL OF MATERIAL BY PART NUMBERS

BILL OF MATERIAL BY ITEM NUMBERS

Check the boxes if you want the BOM item notes list and/or the BOM notes to be displayed on the report. Depress Ok.

The following report will print:

 

BILL OF MATERIAL WITH STANDARD COST

Choose By Item #, By Part #, or Descending Extended Cost from the Detail Report. Depress Ok.

Note: This report takes into consideration the Std Bld Qty when calculating the setup scrap.  You might find the cost calculated in SFT is different from the calculation shown on this report due to,  that if the part UOM is "EACH" and the part has scrap % the code will round it up to next inter number.

 

a)  For the PHANTOM parts in this report the standard cost calculated is based on their components (SUM of component's qty * component standard cost).  Once the standard cost is calculated for the PHANTOM part, the report will treat the PHANTOM part as a single entity on the top assembly BOM and proceed as it was a BUY part with the std cost already entered.

b)  If one of the component parts is a MAKE (not MAKE_BUY) and HAVE components assigned to it, the report will NOT show std cost of the parts itself, it will only show std cost of its subcomponents.
c)  If one of the component parts is a MAKE (not MAKE_BUY) and does NOT HAVE parts assigned to it the report will show std cost of the part itself.

d)  If one of the component part is a MAKE and MAKE_BUY the report will show price for the part itself and will show 0.00 costs for the subcomponents.

e)  If one of the component part is a MAKE and a Phantom/Make the report will NOT display the std price for this part because the report will show the cost of this parts components.

 

Note:  This report will only display the costs for ACTIVE parts and subassemblies as of the date of the report and will NOT include any parts that may have been identified as inactive either in the item master or in the obsolete date of the part on the BOM.

 

The values displayed should be in sync with the Cost Roll Up values.   The following may be why the Standard Cost Roll is different from the Cost BOM Reports.

a)    On the costed BOM Report for a Make/Buy assembly we display the value of the BOM in the costed report, but that total is NOT used in subsequent rollups to higher levels only the standard cost is.  

b)    In Kit Default Setup , user can "Exclude Scrap and Setup Scrap"  in Kitting, MRP, and Cost Rollup, and this will override the "Setup Stcrp" box in the BOM.      Therefore, if user checks "Setup Stcrp" checkbox along with a Standard Bld qty in BOM header, but has the checkbox checked in Kit Default Setup to "Exclude Scrap and Setup Scrap" for Cost Roll, the Cost Roll will NOT calculate the Setup Scrap cost, but this report will always calculate the Setup Scrap cost and this will cause unfavorable Configuration Variances.   For further detail on how Excluding Scrap and Setup Scrap values will affect the variances see Articles #3067, #3053, and #3320 . 

 

The following report will print:  This report ALWAYS includes ALL the parts (including the items flagged as "N" for Used in kit) 

 

 

BILL OF MATERIAL LEAD TIME REPORT

Choose By Lead Time, or By Part # from the Detail Report. Check Ok. The BOM with Lead Time report will add the lead time of the parent part into the lead time field.  So if you have a child part with a Purchase lead time of 30 days, and a parent part with a lead time of 1 day for Kitting and 3 days for Production, the lead time of the child part will be 1+3+30 = 34.

The following report will print:

 

BILL OF MATERIAL, INDENTED WITH WORK CENTER 

BILL OF MATERIAL, OUTDENTED WHERE USED

Select the Inventory Type by choosing the radial.  Enter the Internal Part Number and Rev.  Check the box if you want the  BOM items that are expired or not effective yet to be displayed on the report.

The following report will print:

BILL OF MATERIAL WITH ALTERNATE PART NUMBERS

BILL OF MATERIALS WITH REFERENCE DESIGNATORS & AVL

Check the boxes if you want the BOM item notes list and/or BOM notes to be displayed on the report.    The AVL Order Pref Code will be displayed in front of the Mfgr and Mfgr PN information.   For further detail on exporting to XL format see Article #3319 .

The following report will print:

TOP ASSEMBLY PART USAGE

Select the Product number and applicable revision. Select the quantity by toggling on the up and down arrows. Choose between All Current Components, Used in Kit Components Only and Not used in kit Components by clicking on the desired radial. Choose between Group by Component/Work Center and Show with Parent Assembly by clicking on the desired radial.  Depress Ok.

The following report is printed:

COSTED TOP ASSEMBLY PART USAGE

Select the Product number and applicable revision. Select the quantity by toggling on the up and down arrows. Choose between All Current Components, Used in Kit Components Only and Not used in kit Components by clicking on the desired radial. Choose between Group by Component/Work Center and Show with Parent Assembly by clicking on the desired radial.  Depress Ok.

The following report will print:

 

ManEx’s standard module configuration allows most users to accomplish their daily tasks.  For those users wanting to get more from ManEx by leveraging the total solutions, this is one of the optional modules available for purchase.   To place an order or to learn more about this specific module or any of the other optional modules please contact us at http://manex.com\contactus.aspx

 

To import a BOM, the template qabim.xlt  must be used.  Note:  The module will only recognize and import data that is populated within the "Supplied BOM" worksheet within the template.  The other worksheets are for additional reference only.  After activation, "Express Import to BOM or Quote" access for each user must be setup in the ManEx System Security module.  Users with “Supervisor Rights” will automatically have access.

The BOMASSY, BOMREV, and BOMDESC (highlighted in blue) listed MUST match either what is already in the system , or MUST be listed as a component on the spreadsheet (as shown below in the RED box).  The same assembly and revision cannot be for two different customers.  These fields are required. 

To import a brand new Product/assembly into the system from the spreadsheet, the customer number and the columns in pink are REQUIRED to be completed, as shown below: 

 

 

 

 

 

To import Make or Buy parts to a BOM you must popluate the following fields:  ITEM NO, Part Src, QTY, CPARTMFGR

To import Consigned parts to a BOM you must popluate the following fields:  ITEM NO, Part Src, QTY, CPARTMFGR, CPARTNO and/or CDESCRIP

To import to Quote you must populate the following fields:   ITEM NO, Part Src, QTY, CPARTMFGR, CUSTNO, CPARTNO and/or CDESCRIP

The fields listed on the XLS spreadsheet are:

NOTE:  The Reference Designator field is unlimited in size, and can ONLY accept the following formats or combinations, thereof:

C1, C2, C3, C5, C6, C10, . . . . . . .,

C1-C3, C5-C6, C10,  . . . . . . .,

If there are multiple AVL's for the same component, it is necessary to repeat all the information including the item number and Reference Designators for each AVL, ONLY changing the CPARTMFGR and MFGR PN.  All other information MUST be the same.    See example below.  

 

To provide the capability to load Bills of Material (BOM), to Manex Production and Quotation modules from a simplified Excel spreadsheet.Parts lists, AVL's, and Reference Designators, are all included.

A specific excel template has been created for the module and must be used.There is no limit to the size of the BOMs (number of components), nor to the number of BOMs (assemblies) that can be loaded at one time.The only restrictions are that when loading to a Quote, only one customer may be on the spreadsheet, and when loading to a BOM, only one customer may be associated with a given BOM.

After a preliminary validation of the data, the Import procedure will attempt to locate existing components in the system, and offer the user the choice to use alternate existing components, or to load the spreadsheet again with a different part number.  All NEW part numbers will be loaded into inventory, and the BOMs created.  If there is already an existing BOM, the user will be prompt to decide to override the existing BOM, or ignore the BOM being loaded in the spreadsheet.  If new AVLs are involved with existing parts, the user will be prompt to add the new AVL to the existing part, or create a new part number.  However, it will not overide the material type on existing AVL's, due to the fact that there might be inventory on hand at that time that is not LF (for example) and if we changed the material type upon load it would no longer match the parts on hand.

Once the spreadsheet is completed, it may be loaded from within the Manex Express Import to BOM or Quote Module.

Enter the Express Import to BOM or Quote module and the following screen will appear:

1. Choose to either Import to BOM and Inventory or Import to Quote Module by Selecting the appropriate radial.

• If you choose to Import to Quote Module.  The user will need to select Existing Quote or New Quote. If Existing Quote is selected you must enter in the Quote Number.  If New Quote is selected and system setup is on auto numbering for new quote number, program will not take the next number until the "Load" button is clicked. The last quote number is displayed on the screen in the beginning of the import process.  When the "Load" button is clicked the system will check for the next new number and display a prompt to the user.  When selecting to import to new quote you can only import new products.  To import a brand new Product/assembly into the system from the spreadsheet, the customer number and the columns in pink are REQUIRED to be completed, and MUST match the BOMASSY, BOMREV, and BOMDESC listed in the blue shaded columns.   For further detail see Article #1805 .
• When importing to an existing Quote number through the QBi module, upon depressing the Load button, the system will first find if any products, (disregarding if the product is the same or different from the new import), exist in the Manex under the given quote #.  If the system finds any records it will ask the user whether or not to overwrite them.  If the user selects "Yes" the system will proceed the same way it was always working replacing what ever was under the quote module with new import information.  If the user selects "No" the system will then check if the new import information has any product listed that is the same as the product under the existing quote, and if it does user will be prompted again, but this time if they want to overwrite those records for the products that are the same in both quote and new import file.  If the user chooses "Yes" the system will overwrite existing product information and add any new product to the quote.  If the user chooses "No" the system will only add any new products to the quote. 
• If you choose to Import to BOM and Inventory

There are several validations run at this point, these are a few.  Note:  If the XLS file is not displayed on screen go to your Local_manex directory.  There you should be able to find {{ C:\"_ManexLocal"temp"POExceptionXL}} within that directory is where some of the XLS files that are displayed for your reference could be listed.

If the part Source on the excel template does not exactly match what is in the Part Source Setup (for example: having CONG on the excel template and CONSG setup in Part Source Setup) the following message will be displayed and you may choose to continue or abort.
If there is missing data or invalid data on spreadsheet the following prompt will be displayed and you may choose to continue or abort.

If there are different components with the same item numbers for the same BOM listed on the spreadsheet the following prompt will be displayed. The upload will abort, so you may review the "DupItem.xls" file and correct the spreadsheet.   If users happen to be loading more than one BOM/product into the system on the same spreadsheet and they have the same part number associated with different products with different descrptions that information will also be displayed in an XLS spreadsheet.

If there are incorrect ref designator count on the spreadsheet the following prompt will be displayed.  You may choose to continue or abort to review the XLS file created and correct the spreadsheet.

If the material type has been entered incorrectly on the  spreadsheet the following prompt will be displayed.  You may choose to continue or abort to review the XLS file created and correct the spreadsheet.

Once all the validations are run, The 1: Get File tab appears and the contents of the file are displayed.

 

4.  The user may click on the "Next" button to continue or the "Start Over" button to clear the contents and select another file. Again several validations are run.

If there are multi part sources (same part number listed twice; one as MAKE and one as BUY) listed on the spreadsheet the following warning will appear.  The upload will abort so you may review the "DupSource.xls"  file and correct the spreadsheet.

If the BOM assembly you are uploading does not exist in ManEx as a Customer assembly nor is in the components of the import list or is different than what is listed on the import list this warning will appear.  The upload will abort so you may review the "MissingAssy".xls" file and correct the spreadsheet.

If you are uploading an existing product to the Quote module you will receive the following message.  You can only import new products into the Quote Module. To import a brand new Product/assembly into the system from the spreadsheet, the customer number and the columns in pink are REQUIRED to be completed, and MUST match the BOMASSY, BOMREV, and BOMDESC listed in the blue shaded columns.   For further detail see Article #1805 .

If there is more than one customer listed on the spreadsheet the following warning will appear.  the upload will abort so you may review the "QuoteCust.xls" file and correct the spreadsheet.

If there are more than one customer ID listed on the spreadsheet the following warning will appear.  The upload will abort so you may review the "ConflictCust.xls" file and correct the spreadsheet.

Once all the validations are run, The 2: Check Val tab appears.  If validation of certain data fails, the following screen will be displayed, with a grid of problems, and the User asked to clarify the data.

The first check is to verify that valid Customer Codes are used in the spreadsheet. If one or more invalid customers are found, then a grid will be displayed with the appropriate information, and the user must select an appropriate customer from the drop-down list of customer codes. Or, the user may exit the screen and clarify the spreadsheet.

The next check is to validate that a valid Unit of Measure (UOM) is on each line of the spreadsheet. If an invalid UOM is found, the user is presented with a list of invalid UOMs and may select a valid one from a drop down list of valid UOMs. Or, the user may exit the screen and clarify the spreadsheet.  Clicking on the dropdown arrow will display available Units of Measure to replace the invalid one.

The next check is to validate that correct Manufacturer Codes have been used in the spreadsheet. If not, a grid is displayed with the invalid manufacturer codes, and the use may select from a dropdown list of valid manufacturers to replace the invalid code. Or, the user may exit the screen and clarify the spreadsheet. Clicking on the dropdown arrow will display available Manufacturers to replace the invalid one.  Once the user identifies a MFGR all like MFGRS on the BOM will be updated with the same selection. 

The next check is to validate that correct Source Codes have been used in the spreadsheet. If not, a grid is displayed with the invalid source codes, and the user may select from a dropdown list of valid source codes (BUY, MAKE, CONSG or PHANTOM). Or, the user may exit the screen and clarify the spreadsheet.  Clicking on the dropdown arrow will display available Source Codes to replace the invalid one.

The next check is to ascertain whether or not there is an existing BOM for assemblies contained in the spreadsheet.  If there is, the user must indicate whether or not the existing BOM is to be overwritten with the new data in the spreadsheet. If the user elects to NOT overwrite the existing BOM, the data will not be loaded to the BOM, but the item master will still be updated with any new parts contained in the spreadsheet. Or, the user may exit the screen and clarify the spreadsheet.

5. When all of the foregoing information has been validated or corrected, the user may click on the "Next" button. The program will be sure that all information is valid, and proceed to the next page. Or, it will redirect the user to the invalid information and allow correction of the data.

The 3: AVL tab appears. 

6. Pressing the "Next" button will add the checked AVLs to existing Customer Part Numbers. It will also find all existing parts in the item master and include all inventory item master information with those parts being loaded.

The 4: Rev tab appears.

The import program will search the existing database for parts having the same AVL (Mfgr and Mfrg PN) as the spreadsheet parts, under the same customer part number, but with a different customer revision. The user will be presented with a list of those parts, and may take the option to use them instead of creating a new part number. If accepted (by check box), the alternate customer part number and revision will be used in the BOM.Items not checked will be retained for further disposition in the program.

7. Pressing the "Next" button will revise the checked items to existing (alternate) Customer Part Numbers.

The 5: CPN tab appears.

The import program will search the existing database for parts having the same AVL as the spreadsheet parts, under the ANY CUSTOMER with the same customer part number, and without regard to customer revision. (Some users may use the manufacturers part number for their own.) The user will be presented with a list of those parts, and may take the option to use them instead of creating a new part number.  If accepted (by check box), the alternate customer part number and revision will be used in the BOM. However, the Customer will be added to the customer list for the existing part. Of the checked items, there must be only one check to select an alternate part number, although the search of existing part numbers may find several.  Items not checked will be retained for further disposition in the program.

8. Pressing the "Next" button will revise the checked items to existing (alternate) Customer Part Numbers.

The 6: Alternate CPN tab appears.

The import program will search the existing database for parts having the same AVL as the spreadsheet parts, under the same customer, but with ANY customer part number, and without regard to customer revision. The user will be presented with a list of those parts, and may take the option to use them instead of creating a new part number.  If accepted (by check box), the alternate customer part number and revision will be used in the BOM. However, the Customer will be added to the customer list for the existing part. Items not checked will be retained for further disposition in the program.

9. Pressing the Next button will revise the checked items to existing (alternate) Part Numbers.

The 7: Alternate PN tab appears.

The import program will search the existing database for ANY parts having all the same AVL(s) (Same Mfgr and Mfgr PN) as the spreadsheet parts. 

If the part number listed on the spreadsheet has ALL the same AVL(s) and/or some additional AVL(s), as a part in the system, the user will be presented with a list of those parts, and may take the option to use them instead of creating a new part number.  If accepted (by checkbox), the alternate part number and revision will be used in the BOM, the Customer will be added to the customer list for the existing part, along with any new AVL information from the xls spreadsheet, which is automatically added to the BOM and Inventory Control records.  If the part number listed on the spreadsheet has some AVL(s) that match a part in the system, but not all of them, the system will NOT consider this as an alternative part number.  

Here is an example of why the system will NOT list a part as an Alternative part if only 1 AVL matches and not all AVLs match:  Lets say we have PART A (internal part) with AVL1, AVL2, AVL3.  This part is on the BOM for the customer A.  Lets say the user is loading BOM for customer B and it has PART B (which is NOT in the system yet) with AVL6, AVL7, AVL1. If the system recognized PART A as an alternative to PART B and adds AVL6, AVL7 to the PART A. Then when you go and view BOM for customer A you will see AVL1, AVL2, AVL3, AVL6, and AVL7 on the list of approved manufacturers. This list was changed seamlessly and without real understanding on the users part or without customers consent.  If this is not enough we added X-Ref that will find anything the user want and replace the part selected.

Items not checked will be retained for further disposition in the program. A purple highlight indicates that the item is Inactive.  If the user still elects to use the Inactive part the system will display a warning message that the inactive items selected and the users will option of changing the status to Active.

10.  Pressing the "Next" button will revise the checked items to existing (alternate) Customer Part Numbers.

The 8:Class tab will appear.

The import program will display all parts for which an existing nor alternate part number have been selected. These parts will be new parts added to the item master, and must have additional information included in order to be loaded. The user may select a part class and (optionally) part type for each item or leave it blank.  Blank classes will be assigned "TBD" when loaded into Inventory.   Items for which there are multiple AVLS will only require the class and type to be entered once. The user selects each from a dropdown list. Once a Class is assigned, the available Types for that class will be available for inclusion in the part Type. Because the descriptions are loaded from customer documentation, and the user may wish to clarify the description, the opportunity to do so is on this page.Items not completed will be loaded into the item master with a part class of TBD.

11. Pressing the "Next" button will then search the database for the default information for the class and type, and populate the required fields for the new parts based on the class and type. If no parts have been checked for uploading the system will prompt the user and place them back on the Part Class/Type page.

The 9:Part # & Rev tab appears.

The import program will determine whether or not the user has Auto-Part Numbering enabled.   If it is enabled, the program will assign internal part numbers based on the class and type setups, and move to the next page.  If Auto-Part Numbering is disabled (or off), the user must enter valid internal part numbers and Revisions for each new part.  The internal part number entered may not already exist in the database.   If user wants to use the CustPN and CustRev (from the template) for the internal Part # and Rev check the Copy box.  Checking/Uncheckiing the "Check All" box (located above the CustPN and CustRev columns) will check/uncheck all the records.  If user wants to add the prefix setup for that customer (the prefix must be setup within the Customer Information Module) to the new part number they must check the PRFX box.  Checking/Un-checking the "Check All" box to the far right globally check/uncheck all the records.   Items not completed will NOT be loaded into the item master nor the BOM.

12. Pressing the "Next" button will then search the database to validate the entered part numbers.

The 10:Select to Load tab appears.

The import program will display the entire list of part numbers being entered by assembly.   If the auto numbering is on, user will have the ability to copy the XL revision  to the new part revision by checking the box.  Check/Un-Check All box (located above the Rev column) gives the user the ability to check/uncheck all records to copy the XL Rev to new part Rev.  The user has a final opportunity to verify that the parts and BOMs are to be loaded.  A Check/Un-Check All box is available (located after the Step 10: Select items to Load title) to give the user the ability to check/uncheck all records to be loaded into the item master or the BOM. (In-Active records will have to be manually checked). Items not checked will NOT be loaded into the item master nor the BOM. 

 

This button will take the user to a screen, where they can make a selection by what ever criteria needed by choosing (Internal Part Number, Mfgr Part Number, Customer Part Number, Supplier's Part Number, or Description,etc) to search.  Note:  If a customer selects to "Locate Alternatives for the Highlighted Part" within Step 10, when they import a BOM that uses an existing ManEx PN and adds new AVL(s), the new AVL(s) are NOT added to any existing BOM's.

 

The user can enter partial string and search is not case sensitive.  After system will find parts in response to the search, the user can make a selection by checking on one of the check boxes.  The user can click one of the buttons on the bottom of the screen when done.  And if the user selects one of the buttons with "Select" on it the part that was highlighted in the BOM import screen will be replaced.  Please note the search screen can be up all the time, so if the user selects a part find replacement and click "Select without Exit" button then select next part on the import screen and look for the replacement without exiting search screen.

13. Pressing the "Next" button will then remove the parts that are not to be loaded into the system.

The 11:Select Work Center tab will appear.

The import program will display the entire list of part numbers to be loaded into the item master or BOM. All components will be defaulted to the Staging work center. The user has the option to change the work center at this time.  Highlight the part number you would like to change.Choose a work center from the pull down list.  Click on the Replace Highlighted Records box.

 

14. Pressing the "Load Data" button will complete the upload. The tables updated will be the INVENTOR, INVTMFGR, INVTMFHD, BOM_DET and BOM_REF.

 

If you receive the following message after depressing the "Load Data" button there are a few scenarios that could be causing this message to appear:   1.  A same part, with different description associated with different product, will cause this message to appear upon import. 2.   If the Auto numbering is turned OFF and user has entered the same part number to items with same description but different customer part numbers will cause this message to appear.    When loading one BOM/product at a time into the ManEx System it checks to see if the users might have the same part number,  but with different descriptions or different customer part numbers  loaded on the spreadsheet.  If found then it would display that information in an XLS spreadsheet for the users to address.

 

 

 

 

Header Tab Field Definitions

ECO Number	The number assigned to the ECO, BCN, or Deviation.
Product Number	The unique internal number assigned to the product
Rev	The revision number or character assigned to the product.
Description	The description of the product.
Date Opened	The date the ECO/BCN/Deviation was started.
Type	The type of change, either ECO (Engineering Change Order), BCN (BOM Change Notice), or Deviation.  ECO is for permanent changes to the Inventory Item Master and the Bill of Materials when there is a revision or part number change.  BCN is for permanent changes to the BOM.  Deviation is for a one time change to a work order(s).
ECO Source	This is the source of the ECO, Customer or Internal.This allows the users to know if this ECO was created internally or upon Customer request. At this time this field is for reference only, but will be used for reporting later on.
ECO Ref	An internally assigned reference number.
ECO Lock	If this box is checked, all users can access the screen, but will not be able to edit the record until Aprroved users remove the lock.  When locked the users initials and date will default in.     Note: Users MUST have special rights within the Security module to modify this field.
Last Modified	The users initials and date will default in when modified.
Status	The status of the Engineering Change Order, either Approved, Edit, Pending or Cancelled.
Effective Date	The date that this ECO become effective.  (This Date MUST be prior to the Work Order date to be applied).
Expiration Date	The date that the Deviation will expire.  (This field is only enabled for a deviation and MUST be popluated for the Deviation to be available within the SFT module )
Customer	The name of the Customer which is linked with the Bill Of Materials.
	This button will allow users the ability to load more documents pertaining to the ECO (cutomer ECO,drawings, instructions,etc).  Loaded files will not be carried fwd to the PDM module upon ECO approval.
Purpose of Change	The intent of the change.
ECO Instruction	The description of the change.
	This Button will allow the users to view any hard copy ECO drawing or Documentation loaded. When files have been loaded this button will appear with Red Text.
	This Button will allow the users to view any hard copy ECO drawing or Documentation loaded. When files have been loaded this button will appear with Red Text.

ECO Cost per Unit

Material is the Material Cost Change Total forwarding from the Parts tab. Labor is the Labor Cost Change Total forwarding from the New Build Labor Cost tab. Total is the sum of the changes in Materials and Labor, above.(Note that the signs can be either positive or negative depending upon the changes made.) Note: Users MUST have special rights within the Security module to view the pricing information.

ECO Coordinator	The name of the engineer entering the Engineering Change Order.
Approvals	The name of the department, initials of the approver and the date of approval.  Note: The approving department is setup in the ECO Setup module.
	This button is used for the approval process for each department indicated

Update/Create Records Tab Field Definitions - This tab displays the revised product number, description, changes in Standard Cost, Labor Cost, whether serial number is required and updates for Engineering Change Orders only.  Note:  This tab is not available for Deviations or BCN.

Inventory Changes section:

Product New No:	If the check box is checked, a new product number may be entered here.
New Rev:	If the check box is checked, the new revision character may be added here. Note: that either a new Product No or Rev has to be entered in order for the system to allow the user to save the ECO record – this check has been added to prevent any duplicated inventory records within the system.  See Article #3062 on why the customer part number or revision is not updated at the same time.   NOTE:  When product is changed through ECO module the same material type will be carried fwd for the next/new product at the part level but not at the AVL level.
New Description:	If the check box is checked, a new description may be entered.

Change section:

Matl Cost	If this box is checked, the material cost for the product will be updated based on the changes made within the Parts Section and the inventory part standard cost.
Labor Cost	If this box is checked, the new Labor cost for the product will be updated based on information entered within the ECO New Build Labor Cost section.
Current Value	The mat'l or  labor cost currently existing for the product within the Inventory Control Module.
New Value	The revised mat'l or labor cost for the product.
Serial # Required	If box is checked, user then has the option of checking the "YES" or "NO" box to the right for this part to be a serialized part or not.
No/Yes	If the serial box is checked you have an option to check Yes or No to require the revised product to be a serialized part or not.  NOTE:  This box will remain NO until checked then it will update to YES.
Assigned Customer	This will allow the user to Assign a new Customer to the BOM.   NOTE:  This field is only editable if there are NO open Sales Orders or Work Orders linked to this product.
New Customer Name	If the Assigned Customer box is checked, user may select a customer from the pull down.  Note: Customer name can be changed on the BOM for the product only if either the Product number or revision and the product has no consigned parts for another customer nor any make/phantom parts that are assigned to another customer, and the product is not a sub-assembly for another product.
Open Sales Order List	Shows all SOs (with any status except for cancel) and RMAs with this assembly number, Balance and item number. The selected SOs and RMAs will be updated with the new Product number and/or Rev number and/or Description shown upper left corner. Note: If there have been no items shipped against the sales order selected then the system will just replace the existing product with the new within the Sales Order. If shipments have been made against the item the old line item will be have the Ord Qty updated to equal the total Shipped and the status changed to Closed.A new line item will have been create for the new Product/Rev for the remaining balance that was left on the original item.
Retain Sales Order Prices	Check this box only if you want the Unit Price to remain the same.
Retain Remaining Extra Pricing Items	Check this box only of you want the extra pricing to remain the same. Note:  If you don't check "Retain Sales Order Prices"checkbox, then for either part itself or extra price item, no price will be updated.  The "Retain Remaining Extra Pricing Items" is for adding extra items only, for the "price" column, it's still controlled by "Retain Sales Order Prices" checkbox.
	“Refresh SO” button has been provided so the user can refresh the Sales Order list to check for any new SO created in the system since the ECO was first created.
	This button is depressed to update all records within the system based on the selections made.

The rest of this screen comes up with all of the boxes checked for copying the revisions into the Inventory Master, Production Routing, Product Data Management and Bill of Materials. If the user does not want the assembly copied, the box will be unchecked.

New Build Quote Tab Field Defintions - This tab desplays Labor Costs associated with the build of the new product number and revision and calculates the New labor Cost associated with each new unit.

Rework Quote tab Field Definitions - The Rework Quote tab details any Rework Costs due to reworking the existing quantity in Work In Process and/or Finished Goods Inventory.

Open Work Order List (As of ECO Open Date) window:   Note:  The value of the "as of" is that it can affect the quote pricing and allows customers to better get that information.

Change	A check in this column indicates that the Work Order will be revised to the newly changed product number/revision. The system will automatically update the Work Orders to the newest revision number.  If a kit is in process for the WO selected user MUST depress the "Update Kit" button within the kitting module after the ECO is approved for any part changes to be reflected.   NOTE:   When the ECO takes place and the WO record is updated SFT losses the transfer history for the old revision and starts over with only xfer history for the new revision from that point on.  See Article #3401 for further detail.
Work Order	Shows all WOs (with any status except for cancel) with this assembly number,.  The selected WOs will be updated with the new Product number and/or Rev number and/or Description shown upper left corner.
Balance Qty	This field indicates the quantity remaining in the specific Work Order.
Due Date	Due date from WO.
Status	Status of WO.
Total of Selected WOs	The sum of all of the Balance Quantity column, above.
	Refresh WO button has been provided so the user can refresh the Work Order list to check for any new WO's created in the system since the ECO was first created. The value of the "refresh" is they can refresh after it was created if they created it several days before the quote is ready.

Rework Cost Description window:

Inventory Locations (As of ECO Open Date) window:  Note:  The value of the "as of" is that it can affect the quote pricing and allows customers to better get that information.

Warehouse	The name of the warehouse where the completed product is stored.
Location	The name of the location (such as Row 13, Bin 3) within the warehouse above.
Quantity On Hand	The quantity within that location.
	Refresh Invt Location button has been provided so the user can refresh the Invt Location list to check for any new Locations created in the system since the ECO was first created. The value of the "refresh" is they can refresh after it was created if they created it several days before the quote is ready.
Total	(As of  ECO Open Date)The total of Finished Goods Inventory.  Note:  The value of the "as of" is that it can affect the quote pricing and allows customers to better get that information

The window at the bottom right hand side of the tab will display the total costs associated with the rework. Note that these costs DO NOT forward into either the Inventory Control Item Master nor the Accounting records.They are not associated with any new products which will be manufactured after the update to the latest revision, but pertain only to the costs associated with reworking either existing WIP or Finished Goods.

Totals (As of ECO Open Date):  Note:  The value of the "as of" is that it can affect the quote pricing and allows customers to better get that information

Units to Rework:

Cost to Rework:

Tool & Fixture Quote Field Definitions - Once the ECO record has been approved and updated within the system.  This Tool/Fixture information will then be carried forward into the PDM and Routing Setup modules.

Enter Quality/Engineering/ECO, BCN & Deviation Control Management (EBD) Module

The following screen will appear:

Depressing the Find action button will bring up a selection screen. Select the appropriate radial for the find.

If you select ECO/Deviation No or ECO Reference No radial, then type the desired number into the box. Once you depress the enter key the system will pull up the matching record onto the screen.

If the system does not find a match to the information entered then the following message will be displayed. Answer Yes, and then the system will display a listing of available ECO records to choose from.

 If you select to find by Product No, type the product number into the box. If there is more than one Engineering Change Order, a list of all Engineering Change Orders for that product will appear: Highlight and double click on the ECO/Dev No desired.

If you select to find by Status, a further selection will appear. Choose between New, Edit, Approved, Cancelled or Completed by clicking on the appropriate radial. A list of all of the Engineering Change Orders falling within that category will appear. Highlight and double click on the appropriate record.

Information regarding the ECO, BCN, or deviation, will appear. 

Find an existing ECO, BCN or Deviation.  The information will populate the screen.

Depress the Edit record action button.  Status will change to Edit.

Once the necessary changes have been completed depress the Save record action button to Save changes, or depress the Abandon changes action button to abandon changes.

If the Save record action button is depressed, changes will be saved.  The following screen will appear.  NOTE:  The Approvals will be removed and the ECO changes will need to be re-approved.

The changes will need to be Approved, before the ECO status will change back to Approved.

To add a new ECO, BCN, or Deviation within the system, open the ECO,BCN, & Deviation Control Management (EBD) module.

The following screen will appear.

 

Depress the Add Record Action button. Enter your password. The following selection screen will appear.

If you decide to find an existing Part Number, depress that button. The following selection screen will appear: Type the part number into the red box or highlight it and double click.

If you decide to find the Part Number by Part Class, depress that button. The following selection screen will appear. Type the Part Class into the red box or highlight your selection and double click.

From there a list of all product numbers within that class will appear. Type the Part Number into the red box or highlight your selection and double click.

Information pertaining to that part number will appear on the screen, as follows:

 

 

Select the type of change by depressing the down arrow next to the Type box. An ECO selection is for a permanent change to the Inventory Master, Bill of Materials and Product Data Management (normally a revision added).    NOTE: These records will ONLY be updated if the Revision or Part Number has been changed.   A Deviation selection is for a one time change to existing Finished Goods Inventory and/or Work In Process. A selection of Deviation will not update no records; such as  Inventory Master, Bill of Materials or Product Data Management.(The Update/Create Record tab will be grayed out.)  This is a document for reference only. A BCN selection is to change all part information just like an ECO, but user won't be able to create a new product number/rev, or click any "copy" checkboxes on "Update/Create records" page.  WO and SO lists will also not be available for selections.

Select the ECO Source by depressing the down arrow next the the ECO Source box.

Type in the ECO Reference.

Type in the purpose of the change and Description of change.

Type in the name of the ECO Coordinator.

The screen will appear as follows:

PARTS TAB

Enter the Parts screen

To record an ADD to an ECO record 

Depress the Add Button.

The system will then default to the Status field.  Depress the down arrow next to the Status field. The following choices will appear.   Select Add from the Status listing.

Enter in the new Line No that it will be listed as on the BOM.

Select Source by depressing on the down arrow next to that field. The following selection will appear:

Type in the Part Number. The Revision number, Type, Class, Description, and  AVL information will update automatically.  If the part added has a status of "Inactive" within the Inventory Control Management,  it will be highlighted in purple as an indicator to the user that this item is inactive at this time.  If the user chooses to leave the inactive part on the ECO, that part number record status will automatically be changed to Active upon the "Update Records" button being depressed, so user will not have inactive parts listed on the BOM.  The user will receive a warning that an XLS file has been created for reivew.    

Type in the new quantity to be used in the assembly.

Type in customer part number and rev. if applicable.

 

Scroll over to the right and choose the Work Center by clicking within the Work Center field. The following selection screen will appear.

The system will default into the U/K field, for the component to be included in the kit. You have the option to change this entry to one of the following Yes, No, or Free Stock.

If the user attempts to enter any other characters into this field they will receive the following warning message.

You will then be able to view the Inventory Locations for the highlight part number, by depressing the View Inventory button.The following information will be displayed:

You will also be able to view any Open PO for the highlighted part number, by depressing the View Open POs button.The following information will be displayed:

The AVL info will default in from the Inventory Control module.  You may check or uncheck the approved AVLs.  If the program finds duplicate part numbers in a BOM, any Alternate part number associated with the original line item will be carried fwd to the new item using the same part.  As far as the AVLs, the program will get all unchecked AVLs from all items and to update all items.  For example, BOM item #2 have AVL A,B,C, and D, only C is unchecked.  Now in ECO, user adds item #5, it has AVL A unchecked.  And if item #2 had a alternate part associated with it, that ALT part will also be carroed fwd to Item #5.  We have added a message in the updating routine, if the system does find duplicate Part number, then a message will popup and let the users know then system will take the actions explained above.

To update the Reference designator, enter the character in the prefix box. Indicate the Start number. Depress the Calculate button. The Reference Designator will update. 

To record a DELETE to an ECO  

Depress the Add Button.

The system will then default to the Status field.  Depress the down arrow next to the Status field. The following choices will appear.   Select Delete from the Status listing.

Type in the Bill of Material line Item, that you wish to have removed from the BOM.

The screen will then update with the information pertaining to that item. 

Leave the New Quantity as zero.

If you do not want the part scrapped, scroll to the right and remove the check mark from the Scrap Item field.

To record a CHANGE to an ECO  

 Depress the Add Button.