Automobile parts design diploma mechanical engineering
Process Manufacturing Configuration in EnterpriseOne
1. Prepared by:
Keith Figgins, CPIM
Senior Consultant
Mitchell and Associates
Session ID#: JDE-104910
#MAAIMCS
Process Manufacturing
EnterpriseOne v9.2
Configuration, Costing, Shop Floor Control and
Manufacturing Accounting
2. Agenda
1. Define Process Manufacturing
2. Configuration and Setup
3. Costing
4. Creating and Executing Process WO’s
5. Manufacturing Accounting
3. 1. Definition of Process Manufacturing
Process manufacturing is the branch of manufacturing that is associated with formulas and
manufacturing recipes, and can be contrasted with discrete manufacturing, which is
concerned with bills of material and routing.
■ The simplest and easiest way to grasp the definition of process manufacturing is to
recognize that, once an output is produced by this process, it cannot be distilled or
reworked back to its basic components. In other words, "once you put it together, you
cannot take it apart". A can of soda cannot be returned to its basic components such as
carbonated water, citric acid, potassium benzoate, aspartame, and other ingredients.
Juice cannot be put back into an orange. A plastic card manufactured cannot be
returned to its basic components like PVR sheets, transparent sheets.
A car or computer, on the other hand, can be disassembled and its components, to a large
extent, returned to stock.Process manufacturing is common in the food, beverage,
chemical, pharmaceutical, consumer packaged goods, and biotechnology industries. In
process manufacturing, the relevant factors are ingredients, not parts; formulas, not bill of
materials; and bulk, not individual units.
This is more than a subtle difference in terminology; the terms characterize distinct
manufacturing approaches.
4. 1. Process Manufacturing: Overview
■ Process manufacturing produces products such as liquids, fibers, powders, or
gases. Pharmaceuticals, foodstuffs, and beverages are typical examples of
process products and represent a significant share of the manufacturing
market.
■ Process manufacturing enables multiple products to be made as
coproducts,stocked and sold as separate items; whereas standard discrete
bills of material (P3002) only allow one parent item to be produced per bill
structure. It isnot possible to run or complete a process in terms of decimals.
■ Master routings are not used in process manufacturing because the process
outputs, co and byproducts, are usually different for each process. All of the
variables in the process are controlled by the routing and it is not possible to
make different products with the same ingredients and process.
■ Master routings are used for discrete manufacturing only.
■ Standard Cost is used. Actual or Average Manufacturing costs are not used.
5.
6. 1. Raw Beet to Thick Juice
2. Creating MOL
3. Thick Juice to Crystalized Sugar
4. Molasses to Separator
5. Betaine
6. Wet Pulp to Dry Pulp
Other:
7. Sugar Packaging (Discrete WO’s)
1. Process Manufacturing-Sugar
7. 1. Create weekly Process WO for each Process (6)
2. Record Inventory issues to each Process WO.
3. Record or backflush labor.
4. Backflush machine hours against each WO
5. Record Process Completions every 24 hours
6. Create WIP general Ledger entries daily
7. Materials and labor/machine costs to be recognized at the relevant
process.
8. Close weekly WO’s and record WIP and Variances for the Process
WO’s
1. Process Manufacturing-EnterpriseOne Solution
8. 2. Process Manufacturing Configuration Steps
1. Create item and item branch plant records (G4111/P41026) for
the process, co, byproducts, intermediates
2. Create or validate work centers (G3012/P3006)
3. Enter process routing and operation sequences
(G3012/P3003)
4. Create bill of material, with substitutes (from within
Enter/Change Process)
5. Enter Co/By products list
6. Enter intermediates
7. Run Integrity Analysis (R30601)
8. Setup Costing for Ingredients and Work Centers
9. Simulate and Freeze Costs
10. 2. Process Item Master
Stock Type =R Line Type = M
Process is the Parent Item. No inventory stock maintained.
11. 2. Intermediate Item Master
Stock Type =M Line Type = N
No inventory stock maintained. Consumed in subsequent process.
12. 2. Co Product (Finished Good) Item Master
Stock Type =M Line Type = S
13. 2. By Product (also a Finished Good)
Stock Type =M Line Type = S
14. 2. Relevant Units of Measure
System uses four fields in the Item Master table (F4101) throughout shop floor as
default values in entry forms:
Component, Production, and Primary/Secondary Unit of Measure. Primary Unit
of Measure value must be the smallest of the three units of measure.
Intermediates can be any valid unit of measure as long
as the conversion is set up, however process
manufacturing was not intended to be setup with
Units of Measure conversions for the Process itself.
Since the process is just that, a process, it is a
multiplier for how many of the processes to achieve.
Typically, more than one coproduct is produced by the
process and uses only one bill of material without
using a unit of measure conversion for the process.
The coproducts and ingredients should be set up with
the unit of measure as they are processed.
17. 2. Setup the Process
The 'Cons/Prod' column indicates that ingredients are consumed,
co/byproducts will be produced and outputted at this step, or both
happen. Intermediates on the operation will highlight this field in Pink.
18. 2. Setup the Process
■ Enter the Resource Percent % (RSCP). This field controls how much of
the ingredients are issued for each of the co/by products at a certain step.
Ingredients may be issued separately at time of completion or as a total
issue of all ingredients.
■ The Resource % is used when Inventory Issues (P31113) are called from
Work Order Completions (P31114),and the P31114 Processing Option #
2, Issues Ingredients to Co/By Products, on tab 6, Process Mfg, is set
to'1'.
■ For Completions with Backflush, validate that the ingredient issue type
code is set to 'B' and that the processing option of P31113 (the version
called by P31114) has option # 3, Issue Material For, on the ‘Display’ tab
set to 1. Enter the Op Seq # (Operation Sequence number OPSQ). This
is the routing operation where the co or byproduct is produced from.
■ Enter the Co/By Line # (Component Line Number CPNB).
19. 2. Intermediates are Tied to a Sequence
Intermediate products are items defined as a result of a step but are
automatically consumed in the next step. They are nonstock items and are
only defined steps with a paypoint for reporting purposes. Intermediates
enable the tracking of the quantity of output of any operation in a work
center at a specific time. They can be defined in any unit of measure.
Intermediates cannot be defined as an ingredient in the process in which it is
produced. Set up one intermediate per operation, but do not define an
intermediate for the last operation in a routing instruction
36. 4. WO Completions P31114 Processing Option
JD Edwards EnterpriseOne supports both partial and full work
order Completions (P31114), with or without Backflush, and
Super Backflush (P31123) for completing a process work order.
