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Managing MO’s with OBPMHow to use Browser/PowerLink

technology to revolutionize Manufacturing Orders

Jim Simunek, CPIM

Jim.Simunek@cistech.net

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Introduction• Order Based Production Management (OBPM)

allows for Manufacturing Order:– Create– Change– Receipt (RM) production– Complete, material & labor– Cancel (status 10 orders)– Close (both Force & Normal)

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Introduction• All activity is ‘immediate update’ (i.e. no

batches to close and update)

• Templates can minimize the amount of data entry

• MRP and Reorder Report recommendations can be used to create MO’s and/or PO’s

• Can create MO’s from Customer Order line items

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Introduction• This presentation has been created using

Release 7 (PowerLink)

• Most functions are available at the R6 level also

• This presentation does not address Repetitive Schedules– Schedules are only available for inquiry in

Browser/PowerLink

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EPDM Impacts (R6 & R7)• When using EPDM, MO’s are kept by site

• Site Master file controls– Work List default values– Order Closeout options– Work Center Analysis report default values

• With PDM, data in Site Master is maintained in PC&C tailoring questionnaire

• Order Close & Purge and WIP Value report is by site

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EPDM• Use ‘Site Host Jobs’ to create Work List

reports (can still use Green Screen also)

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Planner File• OBPM has a ‘Planner’ file to create a code file

of valid planner numbers

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Planner Numbers• Item Balance (Warehouse) record holds the

default planner number for the item

• All MRP and MPSP reports and work (green screen) screens sort primarily by planner number

• Planner number is copied into Manufacturing Orders for reports and subsets

• One person can be responsible for multiple planner numbers

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Planner• From the Planner screen, you can display all

MO’s associated with a planner

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Questions?

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Creating MO’s• Template controls initial fields that are

displayed:

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Creating MO’s• With Cards, there is the ability to:

– Pre-assign batch/lot number– Maintain the component allocations– Maintain operations– Add Miscellaneous Charges– Link MO to CO– If using EPDM, copy an Alternate Processes BOM

and Routing to the MO

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Alternate Processes• EPDM allows for the creation of multiple

‘processes’ for the same item – i.e. alternate bills of material and/or routings

• When adding the MO, do NOT check the ‘Include Primary BOM’ and ‘Include Primary Routing’ boxes

• ‘Import’ button on Component and Routing cards allow for Alternate Process to be chosen

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Creating MO’s• When ‘Create Order’ button is pressed, MO is

added (i.e. no ‘Order Release’ required)

• Same files as Green Screen are created:– MOMAST – header information– MODATA – Component Allocations– MOROUT – Operations– MOMISC – Miscellaneous Charges

• Order is added at Status 10 – Open, no Activity

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MO Status CodesOrder Status

• 10 – Open, Not Started• 40 – Activity Reported• 45 – Material Complete• 50 – Labor Complete• 55 – Both Material &

Labor Complete• 99 - Cancelled

Operation Status• 00 – Inactive, labor cannot

be reported• 10 – Open• 30 – Started• 40 – Operation Complete

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Material Transactions• At the present time, can only report Production

Receipt transactions through Browser/PowerLink

• When reporting RM transaction, if there are controlled floorstock components, Planned Issue (IP) transactions will be created

• Pick Complete, Planned Issue, Unplanned Issue, Component Return and Scrap transactions are not available

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Statusing MO’s• Can display open MO’s and PO’s for

component parts allocated to an MO

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Labor Reporting• Labor is not reported through Browser/PowerLink• Labor can be reported through:

– PC&C – green screen labor entry

– PM&C – Job ON and OF transactions

– PaperLess – feeds PM&C

• Per Operation, report– Time spent: Set-up, Run and/or Machine

– Quantity Complete (good)

– Quantity Scrapped

– Operation Complete

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Labor History• Browser/PowerLink will display labor history

transactions• PC&C Control File determines if Labor

Reporting history is kept– If using EPDM, Site record holds Labor History

question

• History is kept regardless of what application is used to report labor

• History is stored in files MOTRAN (open MO) and MOHTRN (MO History)

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Production Receipt (RM)• Can report Production Receipt (RM)

transactions with OBPM

• Template controls fields that will be displayed

• If Controlled Floorstock Components exist, they will be issued (IP transactions)

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Receipt Template

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Backflush Components

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MO Transaction History• Can display transaction history for an MO:

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Completing MO’s • Use OBPM to Complete:

– Material (takes MO to status 45 or 55 if Labor has been previously completed)

– Labor (takes MO to status 50 or 55 if Material has been previously completed)

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Material Complete• If quantity ordered has not been completely

received, ‘Receipt of Material’ card will be displayed to allow RM transaction

• Controlled Floorstock components will be issued

• ‘Material Complete’ card allows for input of Reference, Reason and Date

• If operation scrap has been reported, controlled floorstock components for scrap quantity will be issued

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Material Complete

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Labor Complete• From ‘Maintain’ menu, Labor can be reported

as complete

• Reference and Reason codes can be entered

• ‘Incomplete’ Operations (i.e. Operation Status not equal to 40) can be displayed and completed– Any incomplete operations will be taken to status

40 when Labor Complete is reported

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Labor Complete

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Labor Complete – Incomplete Oper.

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Questions?

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Select MO for Closeout• Can select MO for either normal or force close

– Status 55 (Complete) orders have normal close– Less than status 55 orders must be force closed

• Must select orders for closeout one at a time– If MO’s are taken to Complete (55) status, may

want to use PC&C green screen to select MO’s for close (more efficient)

• Closeout selection does not change MO status• Can Re-Open an order that has been selected

for close

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MO Close

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Production Facility• Can display all MO’s scheduled to go through

a certain Facility

• This is useful if you have outside operations and have made the vendor a Production Facility

• From the Production Facility list, click on a facility, then ‘Display’, then ‘MO Operations Where Used’

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Facility Where Used

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MO Operation Where Used

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Create MO from CO• Can use CO line items to create MO

• Will tie the CO to the MO

• Will use CO quantity and Manufacturing Due Date for MO

• With PTF download, RM transaction for MO will create discrete allocation for CO (must be in a controlled warehouse)

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Create MO from CO

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Create MO from MRP• Can Create MO’s from MRP recommendation

file:

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Create MO from MRP• From MRP Recommendation window, use

‘Customize’ →’Preferences’ to set screen to immediate update

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Component Availability• From MRP Recommendations, you can:

– Highlight multiple planned MO’s (Control + click)– Check component availability

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Check Component Availability

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Check Component Availability

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MO Create from MRP Recommendation

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Summary• OBPM provides much easier access and

reporting to MO’s

• Ability to Create, Maintain, Cancel, Receive, Complete and Re-open makes it much more ‘user friendly’ to report against MO’s

• Ability to display MO’s by Planner or Work Center provides better ‘status’ information

• MRP Recommendations provides component availability capability