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 #5113 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.

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.

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

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.

Enter the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select 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:   Type the Customer into the red box or highlight and double click.
If the user selects by All Customers, the following screen will appear, listing All Customers, Work Centers, and Defects:

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

If the user selects Product Number List, the following list will appear: Type the Part Number into the red box or highlight and double click.
If the user selects All Products, the following screen will appear, listing All Part Numbers, Work Centers, and Defects:

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 screen will appear: User may Select from:  Open, Closed/Cancelled or All The Select from:   Work Order Number, Product Number, Customer, Sales Order Number, or All  Enter complete or partial info into the Red box or highlight and double click.
If the user selects All Work Orders the following screen will appear listing all Work Orders, all Work Centers, and all Defects.

	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 the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select 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.

 

 

 

The user then may select to view just a Customer List, Product Number List, Work Order List, or All Customers, All Products, or All Work Orders.

 

Once they have made their choice, the following screen will appear.  Depending on the selection the following screen may differ.

 

 

  

	In each section, choose from All, One, Some, or Clear.  If you’ve selected one, highlight the desired. If you want some (more than one), depress the Ctrl key and click on the ones desired.  If you want all defects displaying as per the System Setup, check the "Show all defects from systems setup" 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 Pareto Chart - The results being displayed in the Pareto Chart are from Several Work Orders combined.    

Defect Pie Chart -  The results being displayed in the Defect Pie Chart are from several Work Orders Combined. 

 

The formula for the Central line (Green line) is:   c = Total Defects (divided by) Number of Subgroups

The formula for the Upper Control Limit (UCL) (Blue line)  = c + 3 (divided by) p

The formula for the Lower Control Limit (LCL) (Yellow line) = c - 3 (divided by) p (or 0, whichever is greater)

 

 

 

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 01/01/2012 thru 01/31/2012 (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 One Work Order, All Work Centers, and all defects for one day 07/10/2013.    

1^st Pass Yield Chart  The results being displayed are from all Work Orders, Work Centers, and all defects from 01/01/2012 thru 01/31/2012 (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.

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 the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select Quality/Engineer/Corrective Action Request(CAR)/Corrective Action Request (CAR)

The following screen will be displayed:

 

Depress the Find Record action button.

 

The following selections will be displayed: To Find by CAR Number, user must enter the CAR Number into the Red Box

Find by CAR Status

Selecting to find by CAR Status, will display another option to find by Open or Closed CAR's.
Once a user has made the selection of either Open or Closed the system will display a list of CAR's to select from. Select by either entering the CAR number into the red box or highlight and double click on the CAR.

Find by CAR Type

Selecting the find by CAR Type option, user will need to select the Type from the pull down.
Once user has selected the Type from the pull down the a list of CAR will be displayed for this type: : .

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.

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	If locked, all users can access the screen but, will not be able to edit the BOM until Approved  users remove the lock.  This is controlled within the BOM.
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

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

The remaining fields describe Detail information about the component part.

 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 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.

Enter the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select 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.  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 be displayed:   Select the desired Filter:   by selecting the appropriate radio button - Active, Inactive, or All.   Select the desired Find:   by selecting the appropriate radio button - Product Number, Part Class, Customer, or All.   Enter the information into the red box, depress the Enter key and the information will populate the screen.    If you do not know the exact number, Customer, etc you may enter in a partial number, letter, etc, then once you depress the enter key the system will pull up the matching record onto the screen or a list of all BOM's that contain the partial number, letter, etc. entered, to select from. (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 enter information in the Red Box, and system cannot locate any information for the entered product number, part class or customer, user will receive the message being displayed.

If  user selects ANY of the Filters: and Find by All - a screen will appear listing all the Part Numbers with Bill of Materials in numerical order, along with part class and types, descriptions, and status of Inventory Part.  The user has the option to view the BOM by either entering the Part Number into the red box, or scrolling down the list, highlighting the desired record and double click on it. And the information will populate the screen as displayed below:

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 in your password. The following selection screen will be displayed: 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.

If you want a standard build to be considered in Standard Cost calculation, enter the quantity.  See Article 2504 for information on how this affects the Std Cost.

Depress the Save button.

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, a list of all Internal part numbers will appear: Type the internal part number in the red box or highlight and double click to select.

If you select Consigned Part Number, a Customer List will appear: Type the customer into the red box or highlight and double click

A list of all of that customers parts will appear: Type in the customer part number or highlight the item and double click to access. :

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: Say 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 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:

If you select Internal Part Number, a list of all Internal part numbers will appear: Type the internal part number in the red box or highlight and double click to select.

If you select Consigned Part Number, a Customer List will appear: Type the customer into the red box or highlight and double click

A list of all of that customers parts will appear: Type in the customer part number or highlight the item and double click to access. :

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.

The user may find the existing assembly from which to copy either by part number or by part class.

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 user can then either Save the new assembly with all of the components, or Cancel the operation.

Approved AVL's will be retained when copying BOM's except for one exception:  Buy part has 3 AVL's and customer A is associated with buy part and also has 3 AVL's, Create BOM for Customer A add buy part all 3 AVL's will be listed, approved only one of the AVL's on BOM A.   Create new product changing Rev. to B.  Copy BOM A to B.  (BOM B has no customer assigned).  All AVL's will copy over and all will be checked. 

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 obtain the Bill of Material Reports within the Web, select the WEB Print button from the ManEx action buttons at the top of the screen. For further detail on How the Reports work within the Web refer to Article #5477.  (Note:  The only BOM Report available on the WEB right now is the PO BOM Addendum)

Note: In order to access the Reports within the Web the Company Root URL must be setup within the System Appearance module and user must be linked to web within the System Security Module.   

 

Select the Report Type:  BOM - A List of Reports will be displayed that are available on the Web for BOM

 

 

To obtain the Bill of Material Reports within the desktop, select the Print button from the ManEx action buttons at the top of the screen.

 

 

The following reports screen will display a list of reports that are available on the ManEx Desktop: 

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 by Part Numbers

Select if you want to print the Report to the screen or a Printer.  Check the box if you want to  Explode BOM Out to all Levels.   Depress the OK button.

The BOM displayed on screen will print as follows.  (The two PN's boxed in Red are parts that have been exploded out for Sub-Assembiles)

 

BILL OF MATERIAL BY ITEM NUMBERS

Select if you want to print the Report to the screen or a Printer. Check the box if you want to Show BOM item notes list?  Show BOM note? and Explode BOM Out to all Levels? Depress the OK button.

The BOM displayed on screen will print as follows: (The parts in the Red boxes are parts that have been exploded out)

 

 

BILL OF MATERIAL WITH STANDARD COST

Select By Item #, By Part #, or Descending Extended Cost from the Detail Report.   In VFP the system used to take the Std Cost from the Make/Phantom itself even through when a Make/Phantom is added as a sublevel it is always exploded out to the components. So it really should be taking the component values in this case. SQL version of the report will do that. · in VFP the report did not explode out the components for a true Phantom bom - but in SQL version of the report it will. · V VFP did not have the Setup Scrap Cost per individual part number, now that will be available in SQL version · In SQL Version I am still listing the Make/Phantom or Phantoms on the report as reference but they will display as Grey and will not list out the Cost Value     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 BOM displayed on screen will print as follows:  This report ALWAYS includes ALL the parts (including the items flagged as "N" for Used in kit) 

 

BILL OF MATERIALS WITH REFERENCE DESIGNATORS & AVL

Select;  Current, As Of, and All from the Detail Report.   Current =  This report will display the Material Type to the Component Level, and the components on the BOM based off of the Computer Date at the time the report is ran. As Of = This report should function basically the same as the Bill of Material with Ref Designator ~ Current report.  Except that this one will require the users to populate an AS OF date.  Then the resulting report will display the BOM Items based off of that AS OF date compared to the Eff/OB Dates. All =  This report should function basically the same as the Bill of Material with Ref Designator ~ Current report, Except that is will display ALL components that exist on the Obsoleted or not.          This report will also list the Eff date and OB Date.  If either or both of these are blank then the report will not display the information.  It will only display if they are populated.  This way the users can get a good look at ALL the parts that were ever on this BOM and when they become Effective or Obsolete.     Depress Ok.
Check the boxes if you want to Show BOM item notes list? Show BOM note? and Explode BOM Out to all Levels? Depress the OK button.
The following screen will be displayed.  Select "Yes" if you want to export the report to XLS Layout.

If the user selects 'YES' the display will show as follows.  Keep in mind not all of the field could be displayed on this page size, but upon export all fields will be displayed. 
 

 

Select the Export option 



The followng screen will be displayed, Select format 'Excel - Data only'

 

 

The following screen will be displayed,  within the option section be sure to select to include the Header Info 

 

 

 

 

Select file name and destination

 

 

 

XLS results should look very similar to the VFP XLS dumps we have as displayed below 

 

If user selects "No'  to export report to XLS file  The BOM displayed on screen will print as follows:

TOP ASSEMBLY PART USAGE

Enter a quantity.  Select to Ingore Scrap, Setup Scrap, Both, or None.    Select to Suppress Not Used in Kit Items or Not or Use System Default. Depress Ok.

The following report is printed:

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 (if applicable).    If Work Order is shaded in WHITE - that means that this Work Order has no qty in FGI so the system will automatically update the Work Order to the New Revision.  If a kit is in process for the Work Order 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.  If Work Order is shaded in BLUE -  this means that this Work Order is partially completed and will be split into two Work Orders:  The system will change the original Work Order (original product number and revision) build qty to match the qty completed and close this Work Order.  The KIT for that work order will retain only enough material to build the completed quantities.  The system will then create a new work order for new product number/revision for the balance quantity.  All the extra material issued to the original work order will be de-kitted from original Work Order and issued to the new Work Order.   If Work Order is shaded in PINK - These Work Orders are partially completed and some of the issued components are either serialized or lot code traceability activated. These specific components have to be de-kitted manually prior to proceeding.  Or the original Work Order, has to be closed (balance reduced to completed quantities) and extra material de-kitted manually.  Then, the new Work Order has to be created for the balance quantities.
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.
New Work Order	If the Work Order is split into two Work Orders, the number of the New Work created will be listed with in this field.
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.
	Partial WOs button has been provided so the user can view the Work Orders with partial completions that cannot be updated by the ECO process.

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:

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.

Enter the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select Quality/Engineering/ECO,BCN, & Deviation Control Management (EBD) module.

The following screen will be displayed:

 

Depress the Add Record Action button. Enter your password. The following selection screen will be displayed:   Select the desired Filter: by selecting the appropriate radio button - Active, Inactive, or All. Select the desired Find: by selecting the appropriate radio button - Product Number, Part Class, Customer, or All. Enter the information into the red box, depress the Enter key and the information will populate the screen.

If user selects Any of the Filters and Find by All - a screen will appear listing all the Products,  in numerical order, along with the Revision, Part Class, Part Type, Part Number, and Part Status.

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 will NOT be able to create a new product number/rev, or click any "COPY" checkboxes on "Update/Create records" page.  Also, the WO and SO lists will NOT be available for selections when creating a BCN .

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

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:

Enter in the Part Number, and 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.    

Enter in the new quantity to be used in the assembly, and Customer Part Number and Rev. if applicable.

 

Scroll over to the right and select the Work Center by clicking within the Work Center field. The following selection screen will appear.
Note:  The system will give the user the following warning and will not allow user to save the ECO if the same part number and work center are duplicate in ECO.

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.
Enter in the Reference designator(s).   First enter the character in the prefix box, then the Start number. Depress the "Calculate" button and the Reference Designator will update.

You will then be able to view the Inventory Locations for the highlight part number, by depressing the      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       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.

If user enters a part number that already exists in the BOM, but for a different WC, the program will use the AVLs from the new added part number(s) and update the AVLs for the existing part number (as stated in the message received upon Update Records).    For Example:  If a part already exists on the BOM, and now the user adds the same part again (with different WC), and makes changes to the AVL.  When the ECO gets updated, the system will use the new AVL(s) from new added part and update the AVL(s) for existing part.   If I have a part on the BOM already, with 5 part/mfgr/mfgr part no (A,B,C,D,E) and 3 of them (A,C,E) are currently checked on BOM.  Now the user creates an ECO and adds the same part in ECO and changes the AVL to have on (A,B) checked.  When the ECO record gets updated, both parts will now have only (A,B) checked.

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If user adds the same part multiple times to the ECO and doesn't enter the same AVLs for the same part(s) that appears multiple times in the ECO, this message will appear and user must change the AVLs to be the same before they can save the ECO.

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.

Enter 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.  (Note:  This field is for internal reference only, it does NOT affect any other modules).

To record a CHANGE 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 Change Qty from the Status listing.

Enter in the Bill of Material line Item, that you wish to have changed on the BOM.

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

Enter in the new quantity.

Update the Reference Designator information.

In the U/K field, change to if you do not want the change to be used in the kit.

If you do NOT want the item scrapped, remove the check mark from the Scrap Item box  (Note:  This field is for internal reference only, it does NOT affect any other modules).

To change the Work Center where the component is added, depress the down arrow next to the Work Center field.  The following selection screen will be displayed: Make your selection.

UPDATE/CREATE RECORDS TAB

Enter the Update Records screens.(Note:  that if the type was selected as Deviation within the Header screen, then the Update Records screen will be grayed out and unavailable for selection)

Inventory Changes Section:

To update the Material Cost, then check mark the box next to Matl Cost. The new Value field will update based on the changes made within Parts screen.

To update the Labor Cost, then check mark the box next to Labor Cost.  The New Value field will update based on the changes made within the New Build Quote screen.

To require a serial number, then check mark the box next to Serial # Required.  Then go to the box under the New Value column it will remain NO until checked then it will update to YES.

To change or assign a customer, check the Assigned Customer box. Depress the down arrow to see a list of customers.  Select the customer of choice. 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.   NOTE:  This field is only editable if there are NO open Sales Orders or Work Orders linked to this product.

If user is attempting to assign a new customer name to a product with customer consigned parts reporting to it, user will receive the message displayed and will NOT be allowed to change customer name.

If user is attempting to assign a new customer to a product with any Open Sales Orders or Work Orders linked to it they will receive one of the messages displayed and will NOT be able to save the ECO.

In the ECO process of modifying or adding Parts to the ECO, there is a field which contains the Customer Part number, if available. At the present time, this field is empty and non-editable for changing or deleting a part from the BOM. But if the user wishes to add a part, they may do so by entering in either the internal part number or the customer part number in the customer part number field, and the program will locate the corresponding internal part number and enter it. The search is based on the customer part number entered AND the customer associated with the BOM from which the ECO was originated.

Because Manex allows users the ability to use the ECO module to create New Part Numbers via the ECO process, and even assign a new customer to the new part number, we must limit the customer information to that of the original customer, as we cannot determine at what point the reference should change customers, or even if it should. Furthermore, if the user does elect to create a new part number for a new customer, items unchecked on the AVL will transfer to the new bom (if checked on the update sheet). However, there may be a conflict between the AVL of the original customer and the AVL of the new customer, so the user is urged to verify the AVL content of a new bom for a new customer created with this module.

COPY SECTIONS:

Look at the items all ready checked to be copied. If you do not want the items copied, uncheck them.   Note:  When creating new Product within Inventory via ECO change the new Product's AVL will be auto assigned with the Material Type of "Unk".  It will not keep the MT from the original Product the ECO was originated from.

OPEN SALES ORDER LIST:

The Open Sales Order List will include all open Sales Orders including the ones that are flagged as "Admin Hold" and//or "Mfgr Hold",  and any open RMAs against this product. In the Open Sales Order List, check mark within the Change box column if you want the Sales Order and/or RMA to be changed. 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 product and/or revision within the Sales Order. If there have been shipments made against the item the old line item will have the Ord Qty updated to equal the total Shipped and the status changed to Closed. A new line item will have been created for the new Product/Rev for the remaining balance that was left on the original item. If you do NOT want the price changes to affect the sales order prices check the "Retain Sales Order Prices" box.  If you would like to retain any extra charges against the line item check the "Retain Remaining Extra Pricing Items" box.  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.

The completed screen will appear as follows:

NEW BUILD QUOTE TAB

Enter the New Build Quote screen.

To add a new Labor Cost associated with the new revision, depress Add the button. Type in the Labor Cost Description. Type in the new revision cost per unit. Continue to Add as required.

REWORK QUOTE TAB

Depress the OK button to continue.

If Work Order is shaded in WHITE - that means that this Work Order has no qty in FGI so the system will automatically update the Work Order to the New Revision.  If a kit is in process for the Work Order 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. 

If Work Order is shaded in BLUE -  this means that this Work Order is partially completed and will be split into two Work Orders:  The system will change the original Work Order (original product number and revision) build qty to match the qty completed and close this Work Order.  The KIT for that work order will retain only enough material to build the completed quantities.  The system will then create a new work order for new product number/revision for the balance quantity.  All the extra material issued to the original work order will be de-kitted from original Work Order and issued to the new Work Order. 

 If Work Order is shaded in PINK - These Work Orders are partially completed and some of the issued components are either serialized or lot code traceability activated. These specific components have to be de-kitted manually prior to proceeding.  Or the original Work Order, has to be closed (balance reduced to completed quantities) and extra material de-kitted manually.  Then, the new Work Order has to be created for the balance quantities.

If needed, you have the option to refresh the Work Order listing to see if any new Work Orders have been created for this product since this ECO was originally opened, by depressing the "Refresh WO" button.

To add costs solely associated with the rework of open Work Orders and/or Finished Goods Inventory, depress the Add button under the Rework Cost Description window. Type in the Rework Cost Description and the related cost per unit.

The Inventory Locations (As of ECO Open Date), will default in and is for reference only.

The Totals (As of ECO Open Date) will default in displaying the quantity in WIP and the quantity in FGI.  The Units to Rework and the Cost to Rework will update automatically.  

If any new Work Order's were created they will be displayed in the "New Work Order" field for reference:   

TOOL & FIXTURE QUOTE TAB

To add new Tool/Fixture Information, depress the Add button below the section.

Add the Tool/Fixture information from the pull down.

Choose the Work Center from the pull down.

Fill in the cost amount, Charge Amount, Effective Date, and Termination Date.

Once the ECO record has been approved and updated within the system, this Tool/Fixture information will be carried forward into the PDM and Routing Setup modules.

The completed screen will appears as follows:

Depress the Header tab. Note that the ECO Cost/Unit columns have updated at the bottom left hand side of the screen:

Depress the Save record action button or the Abandon changes action button.

Upon Saving the user may be given a message if one or more of the parts do not have the same number of reference designators as the new quantity within the ECO, or BCN. This is giving the users the option to print out a report to list these item or not.

If Yes is selected the report, ECO Report Incorrect number of reference designators will go directly to the default printer and the next message will be displayed.

The user now has the option to cancel out of the save or continue.

The user should go back to the reference designators section for the part listed in the report and change the number of designators to equal the quantity required.

The Approval button will be available. Depress the Approval button.  You will be prompted for the appropriate department password. Continue this process until all of the departmental approvals have been entered, as displayed:

Once all of the Approvals have been fulfilled then within the Update Records tab the “Update All Records" button will become available.

Depress the Update All Records button. The records you selected will update. The ECO or BCN will now show with the following Updated time stamp.

 

 

Overview:

The difference between the ECO and the Deviation is: A Deviation is a method to document and approve a temporary change from the normal operation until an ECO is created to replace the Deviation, it is only a record that someone approved a change in some method for a work order(s).  That is the reason the Deviation has an Expiration Date field in the main page and it will not update any active modules, part number change, rev change, description change or anything else.  Whereas, ECO is a permanent change and change the part number, or rev or description, or standard cost, or anything thing else including updating any or all active files.

The basic procedure of processing a Deviation follow basically the same rules as a Regular ECO except for the Update Records button is disabled.

Enter the ECO module. Depress the Add Record action button Select the desired product number. Then for the Type Select Deviation

Once Deviation has been selected as the Type,  continue on and enter in the remaining Deviation information as explained in the Adding ECO section above.  Note:  For a Deviation you MUST make sure you complete the expiration date so users know that it is for a limited period of time.  If this field is left blank the deviation will NOT be displayed in the SFT module.

Note:  The Update Create Records tab will remain grayed out and unavailable for any Deviation records entered within the system.

Once the Deviation has been completed the normal list of Approvals need to be entered.

The status of the Deviation record will update to Approved.

Changing the status of a Deviation from Approved to Completed.

Find the desired Deviation record.

Depress the Edit record action button. Click on the down arrow next to the Status field, the following selections will be available for Deviations.

 

 

 

Enter the ECO module. Find an existing ECO record within the system.

Depress the Copy Record action button. The following message will be displayed:

 

 

The following selection will appear: 

 

• ECO Type
• ECO Source
• Customer  (if applicable)
• Purpose of Change
• ECO Instructions
• ECO Cost/Unit 
• ECO Coordinator

• New Values (if applicable)

• Labor Cost Description

• Rework Cost Description

To obtain the ECO Reports within the Web, select the WEB Print button from the ManEx action buttons at the top of the screen. For further detail on How the Reports work within the Web refer to Article #5477.

Note: In order to access the Reports within the Web the Company Root URL must be setup within the System Appearance module and user must be linked to web within the System Security Module.

Select the Report Type:  ECO - A List of Reports will be displayed that are available on the Web for ECO 

To obtain the ECO Reports within the desktop, select the Print button from the ManEx action buttons at the top of the screen.

 

The following reports screen will display a list of reports that are available on the ManEx Desktop:

PRINT OUT OF ECO REPORT

The ECO record that is open within the ECO module will default in – but the user does have the option to enter in a different ECO # record if desired.

The ECO Printout Report will appear as follows:

ECO STATUS REPORT 

If you highlight the ECO Status Report and then depress the OK button and the following screen will be displayed:

Select the ECO Status and ECO Type by pressing on the down arrow next to the window. Highlight the desired status.

Enter the Customer:  (If All Customer are desired leave * as default)  NOTE:  You MUST enter a Customer or have the default (*) for this report to work. If the ECO record does NOT have a Customer selected, then it will NOT appear on this report.

Enter Starting Date Range and Ending Date Range in "yyyy-mm-dd" format

Enter Starting Part Range and Ending Part Range:  (If all parts are desired leave * as default)

Depress the OK button. The following ECO Status Report will appear as follows:

The Work Order Traveler Setup module is used to define the details of the Production Work Order Traveler Setup for a product.   Certain work centers are “hard-coded” into the ManEx program. These are Material Staging, Finished Goods, RWRK, RWRKQC and Scrap. These work centers may not be modified by the user, or omitted from a Work Order Traveler Setup, because they are associated with special codes that are essential to our system.
 
For example:  "STAG"  is the first step so when a Work Order is created the material can go into Staging.  

"FGI"  when material is moved into finished goods a number of thing happen within the system, (1. Receiving into the inventory; 2. accounting transaction WIP to inventory, etc.) 

RWRK and RWRKQC are used to move material directly to Rework Work center and rework Quality Control Work center. Would be used for RMA's ect... 

"SCRP" - if material is moved into scrap or MRB some GL transactions are associated with the move. 

They are the gateways to and from the Work Order Traveler Setup for WIP management.

The Work Order Release Check List tab is for the user to select check list items for the Work Center listed in the Current Work Center field.  The Work Order Release Check List is set up in the Shop Floor Tracking Default set up screen.  In this module, the Check List items are selected, as detailed. Then when the user reaches the Work Order Shop Floor Tracking module, the items added in this module will be available.

Fields &  Definitions 

The Outsource tab shows the services to be performed outside of the user’s shop. These services are indicated with an “O” in the work center tab.

 Within the window, the 1^st column is the abbreviation used for the activity and the 2^nd column is the full activity for the Work Center listed. The list of activities are set up in System setup – Production Work Centers & Activities Setup.

Enter the SQLMANEX.EXE (within the ManEx root directory) This action will then prompt the user for a password
The following screen will be displayed, select Quality Engineering/Work Order Traveler Setup

The following screen will be displayed:

In this screen, a Work Order Traveler setup is either Created or Edited. 

 

Depress the Find record icon, the following dialog box will be displayed:  If user elects to find by the Product Number or by  Part Class they must enter in the Product Number or Part Class in Red box.   If you do not know the exact number, Customer, etc you may enter in a partial number, letter, etc, then once you depress the enter key the system will pull up the matching record onto the screen or a list of all Part Numbers that contain the partial number, letter, etc. entered, to select from. 

 

 

 

If user elects to find by selecting the "All" radio button.   The user selects the desired product by either entering it into the red box, or scrolling down the list and double-clicking on the desired product. 

 

 

The following screen will be displayed with the data for the selected product.  

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Setup a Work Order/Traveler Routing

Find the desired Product number record.  

Depress the Edit button from the main tool bar: 

Note: Users MUST have special rights within the Security module to check the "Traveler Released" box.  Users with “supervisor’s rights” will automatically have access.    This box must be check when usiing the Unreleased Work Order List and the Work Center Checklist .

User may Add/Delete Work Centers, by depressing the     button and a screen then fills the right side with all of the standard work centers (setup within the Production WC/Activity Setup module).

Work Centers may be moved to either side by double clicking on the side from which to move.

If the user wishes to add all work centers to the Work Order Traveler Setup, then remove a few unwanted ones, pressing the “Add All” button will transfer all work centers to the Work Order Traveler Setup. Likewise, pressing the “Remove All” button will remove all but the fixed work centers from the Work Order Traveler Setup.

Work Order Traveler Setups may be added more than once, to accommodate multiple visits to the same work area during production (e.g. test). 

Depress the Done button when the movement is completed.

The  "Reorder" button allows the user to reorder the Work Order Traveler Setup in any order desired. Pressing this button will bring up ordering buttons on the left side of each work center in the Product Work Order Traveler Setup.  The user may then click on any of these buttons and drag a work center to the desired order.

Depress the Done button when the reordering is completed.  

 




"Starting Work Center for Tracking Serial No"  Choose from the pull down which Work Center you would like to begin tracking the Serial numbers.  The system does NOT allow selection of "FGI" or "SCRP" as a starting WC for Serialization, because this will cause the system to become stuck between SFT and Serial number assignment.   NOTE:   If the starting work center is removed, when user clicks “Update WO” button, all the WC qty and SN (if any) except for FGI, RWRK, RWQC, and SCRP work centers will be moved back to STAG work center because the system will treat the STAG as the starting tracking SN work center.   







User may enter/edit the WC Setup/Run time or the PPM.   The user should place the cursor on the work center to be edited, then on the times to be edited.  The user may modify one or more Work Centers. 

The area labeled "All Work Centers", will show the total times of all work centers and/or activities. This will automatically update. 

 

Note:  There are two different ways to track SETUP and RUN times for Job Costing and Product Data Management in ManEx.

 

1.    By entering Run and Setup Times in the Work Order Traveler Setup under Production Planning.

2.    By entering the Run and Setup Times in Activities Setup under the Work Center Setup.

Using the first choice is preferred when there is a great variability in the products produced and the setup and run rates in each work center. The second choice is preferred when the product flow is uniform, the machine rates are well established and the setup times very uniform regardless of product. The choice is made in the Production Schedule Setup module. Use of Run and Setup Times is optional unless Job Costing module is in use.

Then depress the Save button from the main tool bar to save the changes and the Update Open Work order button becomes enabled.

Update Open Work Orders

This button allows the user the option to update specific work orders which will then reflect the modified Work Order Traveler Setup. Otherwise, current Work Orders will NOT be updated, but future Work Orders created will carry the modified Work Order Traveler Setup. Depressing the button will bring up the following screen: To select multiple items in the list, hold the Ctrl key down and click on those items you want to update. Depress the OK button.

 After modification, the user must either Save or Cancel the modifications. 

Find the desired Product Number, that you wish to have updated.

Depress the Copy Record icon.  The following message will be displayed:        Depress "OK"
If user elects to find by the Product Number or by  Part Class they must enter in the Product Number or Part Class in Red box If user elects to find by selecting the "All" radio button a list of all the Active Product numbers will be displayed.   The user selects the desired product by either entering it into the red box, or scrolling down the list and double-clicking on the desired product.
The user may elect to copy only the Work Order Routing, or the Work Order Routing and Instructions. The Setup Times/Run Times, for Work Centers and Activities, WO Release Check List, Tooling, and Outsource information will also be copied.

Note:  if a Work Center has activities associated with it, the “ACTIVITIES” tab will be showing in RED font.

 

Activities may be moved to either side by double clicking on the side from which to move.

The  button will allow the addition or deletion of activities associated with the Work Center. The activities listed on the right side will show only activities associated with the work center in the system setup.  Activities may be moved to either side by double clicking on the side from which to move.

 

If the user wishes to add all activities, then remove a few unwanted ones, pressing the “Add All” button will transfer all activities to the Work Order Traveler Setup. Likewise, pressing the “Remove All” button will remove all activities from the Work Order Traveler Setup.

The "Reorder" button allows the user to reorder the activities in any order desired. Pressing this button will bring up ordering buttons on the left side of each activity in the Product Work Order Traveler Setup.   The user may then click on any of these buttons and drag an activity to the desired order.

Adding/Editing Tooling Information  

The Tooling tab is used to describe the tooling requirements for the Work Center. It also provides for a location notation and an Expire Date. An example of a Check List item might be to perform the Work Center tooling, as detailed in this tab.

 

Depress the Edit button from the main tool bar, or enter the Tooling screen then depress the Edit button from the main tool bar: 

Select the Tool/Fixture Description from the pull down selections (setup within the Tools Setup module).
Select the Work Center from the pull down menu:

To delete a line item from the Tooling Tab. Highlight the line item.  Depress the Delete button, the following message will appear.  Select Yes to continue the deletion, select No to abandon the deletion.

After modification, the user must either Save or Cancel the modifications. 

Highlight the Outsource Service, then go to the Outsource Tab and the following screen will appear:



Highlight the Outsource Service. Depress the Add button for the Supplier. Select the Supplier from the pull down.  

Then continue across the columns and enter the quantity, cost each and markup. The Charge column will automatically update. When data entry is complete, depress the Done button.

 

If the "Certificate Required" box is checked, this indicates that the supplier of the outsourced service is required to provide a certificate of completion.

Depress the "Service Footnote" to attach a footnote regarding the services for this product.