ADempiere User Manual

Part C

Manufacturing

Copyr i gh t

This document is Copyright © 2008 by its contributors as listed in the section titledAuthors. You can distribute it and/or modify it under the terms of either the GNU GeneralPublic License, version 2 or later (http://www.gnu.org/licenses/gpl.html), or the CreativeCommons Attribution License, version 3.0 (http://creativecommons.org/licenses/by/3.0/)or later.

All trademarks within this guide belong to their legitimate owners.

Author sHeinz-Günter Siebert (Oscar)Bepi Esposito VingianoPelgrim(other contributors will be added)

FeedbackMaintainer of this document: Heinz-Günter Siebert Please direct any comments or suggestions about this document to:adempiere@siebert-edv-beratung.de

Pub l i ca t ion date and so f tware ver s ion

Published: 4 th June, 2008. Based on Adempiere Version 3.5.1a Revision 5331 – Doc.Version 0.1

Update: 8 th June, 2008. - Chapter Organisation added / Chapter renumbering – Doc.Version 0.2

Table of Content 1 Organisation......................................................................................................................................5

1.1 Client Organisation...................................................................................................................5 1.2 Production configuration..........................................................................................................5

2 Change Notice..................................................................................................................................7 2.1 Change Notice...........................................................................................................................7 2.2 BOM Change Notice................................................................................................................8

3 Engineering Management.................................................................................................................9 3.1 Resource Manufacturing...........................................................................................................9

3.1.1 Resource Type...................................................................................................................9 3.1.2 Manufacturing Resource.................................................................................................10

3.2 Manufacturing Workflow........................................................................................................11 3.2.1 Manufacturing Workflow setup......................................................................................12 3.2.2 Manufacturing Workflows..............................................................................................12 3.2.3 Workflow Editor..............................................................................................................14

3.3 Bill of Material & Formulas..................................................................................................15 3.3.1 Workflow Editor..............................................................................................................15 3.3.2 Bill of Material & Formula.............................................................................................16 3.3.3 BOM & Formula Info.....................................................................................................16 3.3.4 Multi Level BOM & Formula Detail..............................................................................17 3.3.5 Multiple Components Change........................................................................................17 3.3.6 Product Configuration BOM...........................................................................................18

4 Planning Management....................................................................................................................19 4.1 Planning Management Setup..................................................................................................19 4.2 Product Data Planning............................................................................................................19

4.2.1 Product Planning.............................................................................................................19 4.2.2 Create Product Planning..................................................................................................20 4.2.3 Forecast...........................................................................................................................22

4.3 Material Resource Planning – MRP.......................................................................................23 4.3.1 Material Requirement Planning setup.............................................................................23 4.3.2 Calculate Low Level.......................................................................................................23 4.3.3 Create Record MRP........................................................................................................24 4.3.4 Calculate Material Plan...................................................................................................24 4.3.5 MRP Info.........................................................................................................................25 4.3.6 MRP Notice.....................................................................................................................25 4.3.7 MRP Details....................................................................................................................26 4.3.8 Planned Order Approval..................................................................................................26

4.4 Capacity Requirements Planning - CRP.................................................................................27 4.4.1 Capacity Requirement Planning Setup...........................................................................27 4.4.2 Calculate Capacity Plan..................................................................................................27 4.4.3 Resource Load View.......................................................................................................28 4.4.4 CRP Info..........................................................................................................................28

4.5 Distribution Resource Planning - DRP...................................................................................29 4.5.1 Distribution Resource Planning Setup............................................................................29 4.5.2 Calculate Distribution Plan.............................................................................................30 4.5.3 DRP Details.....................................................................................................................30

5 Production Management.................................................................................................................31 5.1 Discrete Manufacturing..........................................................................................................31

5.1.1 Discrete Manufacturing Setup .......................................................................................31 5.1.2 Manufacturing Order.......................................................................................................32 5.1.3 Manufacturing Orders Review........................................................................................33

5.1.4 Component Check...........................................................................................................33 5.1.5 Print & Release Order.....................................................................................................34 5.1.6 Order Receipt & Issue.....................................................................................................35 5.1.7 Inventory in Process........................................................................................................35 5.1.8 Order Transactions..........................................................................................................36 5.1.9 Management Maintenance..............................................................................................36

5.2 Shop Floor Control.................................................................................................................37 5.2.1 Activity Control Report...................................................................................................37 5.2.2 Shop Floor Transaction Details.......................................................................................37

6 Distribution Management...............................................................................................................38 6.1 Distribution Management Setup.............................................................................................38 6.2 Distribution Network..............................................................................................................38 6.3 Freight Category.....................................................................................................................39 6.4 Shipper....................................................................................................................................39 6.5 Distribution Order...................................................................................................................40 6.6 Generate Movement - Manual................................................................................................41 6.7 Generate Movement - Process................................................................................................42 6.8 Inventory Move.......................................................................................................................43

7 Quality Management.....................................................................................................................45 7.1 Quality Specifications.............................................................................................................45 7.2 Bill of Materials & Formula...................................................................................................46 7.3 Print Test Results....................................................................................................................46

8 Standard Costing Management.......................................................................................................47 8.1 Create Doc Type to Manufacturing.........................................................................................47 8.2 Create Element........................................................................................................................47 8.3 Product Costing.......................................................................................................................48 8.4 Copy Price to Standard Cost...................................................................................................48 8.5 Workflow Cost Roll-Up..........................................................................................................49 8.6 Cost Workflow & Process Details..........................................................................................49 8.7 Bill of Material & Formula Cost Roll-Up..............................................................................50 8.8 Cost Collector.........................................................................................................................50

1 OrganisationWith the introduction of the new Libero (Manufacturing), it seems quite reasonable to replace the Garden World Admin Sample with a more production like sample Client. The new sample client will be the ADinc (AD) with an appropriate organisation.

This issue raised when starting the ADempiere Documentation Project. There are three (initially – perhaps more to come) goals, which are targeted:

● Get a common understanding of the sample client

● Have a common document as a base for translation

○ The multis will show additional complexity

○ Common base of understanding

● Synchronize testing and documentation

1.1 Client OrganisationIn addition to get a common understandig about the functionality of Adempiere, the proposal to have an production oriented org-chart the following org-chart will be used to explain the functionality .

Durint creation of a new client for the fictionary Caompany ADinc (AD later on) the two default users adminAD and userAD are created. The other user are build using a two byte prefix and a continuous suffix.

1.2 Production configurationTo have a basis for general dicussions, testing, a common sense of understanding, the production configuration will be defined here. There has to be a manufacturing client organisation as a basis for common understanding. The name of the organisation will be ADinc (called AD). The default userids will be adminAD and clientAD. In addition there will be one sales person sd1, five workers in production {pp1, ..., pp5}, one CO co1, which is responsible for bookkeeping and procurement. Furthermore there are three vendors {vd1, vd2, vd3} and some customers {cu1, ...cun}.

Production of products {P1, P2}

Manufacturing Level 0

ProductP1

Product P2

1 2 * C1 2 * C2 + 2 * C3

2 1 * a1 + 1 * a2 + 3 * a3 2 * a1 + 1 * a2 1 * a1 + 3 * b3 2 * b1 + 2 * b2 1 * c1 + 1 * c2 1 * c2 + 1 * c3

Px = productsC* = components

{ax, by, cz} = elements

2 Change Notice

2.1 Change Notice

2.2 BOM Change Notice

3 Engineering Management

Engineering Management is the process, which delivers ...

3.1 Resource ManufacturingThe intention of Resource Manufacturing define Resource Types and Manufacturing Resources.

3.1.1 Resource TypeThe Resource Type describes the type of Resource :-)

The Resource Type is used as S_ResourceType_ID in the following tables:

But what is the meaning ? Try to find out in java-code.

S_ResourceType_ID is used in the following modules:

● org.eevolution.model.MPPMRP.java ○ "SELECT mrp.PP_MRP_ID FROM PP_MRP mrp WHERE mrp.M_ForecastLine_ID = ?

○ "SELECT mrp.PP_MRP_ID FROM PP_MRP mrp WHERE mrp.C_OrderLine_ID = ? ");

○ SELECT PP_Order_ID FROM PP_Order o WHERE o.AD_Client_ID = ? AND o.C_OrderLine_ID = ?

○ SELECT PP_Product_BOM_ID FROM PP_Product_BOM bom WHERE bom.AD_Client_ID = ? AND bom.Value = ?

○ SELECT S_Resource_ID FROM S_Resource r WHERE r.ManufacturingResourceType = 'PT' AND r.IsManufacturingResource = 'Y' AND r.AD_Client_ID = ? AND r.M_Warehouse_ID = ? AND ROWNUM = 1

○ SELECT * FROM PP_MRP WHERE Type = 'S' AND TypeMRP='MOP' AND PP_Order_ID = ?

○ SELECT * FROM PP_Order_BOMLine bl WHERE bl.PP_Order_ID= ?

○ SELECT * FROM PP_MRP mrp WHERE mrp.Type = 'D' AND mrp.TypeMRP='MOP' AND mrp.PP_Order_BOMLine_ID = ?

○ SELECT * FROM PP_MRP mrp WHERE mrp.Type = 'D' AND mrp.TypeMRP='DOO' AND mrp.DD_OrderLine_ID = ?

○ SELECT * FROM PP_MRP mrp WHERE mrp.Type = 'S' AND mrp.TypeMRP='DOO' AND mrp.DD_OrderLine_ID = ?

○ SELECT * FROM PP_MRP mrp WHERE mrp.M_RequisitionLine_ID = ?

○ SELECT * FROM PP_MRP mrp WHERE mrp.M_Requisition_ID = ?

● org.eevolution.model.X_S_Resource.java

○ What does the „S“-prefix stands for ?

● org.eevolution.model.reasoner.CRPReasoner.java○ // Checks the requested resource id directly on order node, not on resource id of the order

"PP_order_id in (select PP_order_id from PP_order_node where s_resource_id="+r.get_ID()

// ... and only the orders running on given day

+" AND ("+getDayRestriction(dateTime, r)+") ) AND AD_Client_ID =" + r.getAD_Client_ID();

○ PO.getAllIDs("S_ResourceUnAvailable", "S_Resource_ID = "+r.get_ID()

● org.eevolution.process.CRP.java○ Forward scheduling

○ Backward scheduling

● org.eevolution.process.CRPSummary.java○ SELECT SUM( CASE WHEN ow.DurationUnit = 's' THEN 1 * (onode.QueuingTime +

onode.SetupTime + (onode.Duration * (o.QtyOrdered - o.QtyDelivered - o.QtyScrap)) + onode.MovingTime + onode.WaitingTime) WHEN ow.DurationUnit = 'm' THEN 60 * (on ...

3.1.2 Manufacturing ResourceA Manufacturing Resource is of a specific type (S_ResourceType_ID). This can be man and/or machines or something (?) else.

A manufacturing resource will be used to support the manufacturing of products. This resource will create costs and will use time.

If „IsManufacturingResource“ checkbox is activated, the following fields will be displayed:

● ManufacturingResourceType

● DailyCapacity

● PercentageUtilization

● QueuingTime

● WaitingTime

3.2 Manufacturing WorkflowThe idea of the manufacturing workflow is

3.2.1 Manufacturing Workflow setupThe Manufacturing Workflow consists of four nodes:

● Resource Type

● Warehouse & Locators

● Manufacturing Resource

● Manufacturing Workflows

3.2.2 Manufacturing Workflows

3.2.3 Workflow Editor

This Menu item does provide an interface to serach for specifc workflow to be edited.

3.3 Bill of Material & Formulas

3.3.1 Workflow Editor

3.3.2 Bill of Material & Formula

3.3.3 BOM & Formula Info

3.3.4 Multi Level BOM & Formula Detail

3.3.5 Multiple Components Change

3.3.6 Product Configuration BOM

4 Planning ManagementBefore the manufacturing process will be started, it is necessary to plan all activities which are required to deliver all required components and material in time. Planning Management does answer the question: What is the optimal input for manufacturing to fullfil sales orders in time and keep warehosue costs at a minimum.

4.1 Planning Management Setup

4.2 Product Data Planning

4.2.1 Product Planning

4.2.2 Create Product PlanningIn order to facilitate to load planning data of similiar products, one can run teh process „Create Product Planning“ and this process will create the data planning register for every product, which fits the parameters: Product Category, Warehouse and Resource. One must indicate the planning parameters defined in the last section for every Product Category, Warehouse and Resource Set. Every Product which does fit with these three parameters will hava a data planning record with the same data planning values you enter in this form.

4.2.3 Forecast

4.3 Material Resource Planning – MRPMRP is a set of techniques which uses Bills of Meterial, Inventory Data and Master Production Schedule (MPS) to calculate requirements for materials. It does create planned manufacturing orders to balance demand and supply for products and it does issue recommendations to receipt material with the right quantities and just in time to satisfy the MPS in teh most efficient way.

4.3.1 Material Requirement Planning setup

4.3.2 Calculate Low Level

4.3.3 Create Record MRP

4.3.4 Calculate Material Plan

4.3.5 MRP Info

4.3.6 MRP Notice

4.3.7 MRP Details

4.3.8 Planned Order Approval

4.4 Capacity Requirements Planning - CRPThe process of Capacity Plan Calculation allows us to know the available time in each manufacturing resource, as well as teh required time to satisfy the Master Production Schedule (MPS). It is a set of techniques which uses the planned manufacturing orders by MRP, open manufacturing resources and the workflows to calculate the required time for each resource along with the available time. With this information, we are able to balance teh time demand with the available time. Though the knowledge of the required and available capabilities it is possible to adjust the MPS until we arrive at a realistic time.

4.4.1 Capacity Requirement Planning Setup

4.4.2 Calculate Capacity Plan

4.4.3 Resource Load View

4.4.4 CRP Info

4.5 Distribution Resource Planning - DRP

4.5.1 Distribution Resource Planning Setup

4.5.2 Calculate Distribution Plan

4.5.3 DRP Details

5 Production Management

5.1 Discrete Manufacturing

5.1.1 Discrete Manufacturing Setup Once the production planning process is completed1, the production control process allow the check the execution activities in order to garantuee to hold the material plan. Each time one needs to release a manufacturing order, the required components, material, man and machines are completely available in the warehouse. This is achieved by tracking the manufacturing release and due dates for every component, required to fullfil the initiating sales order. This is easy to get, using the shortage reports from this (?) module.

This module is responsible to answer the question: What do I need to accomplish the Master Production Schedule (MPS) ? If one cannot cover the MPS as planned, this module provides information required to decrease the negative effects on costs (reduce warehouse costs) and customer service (deliver in time).

1 Checklist ??

5.1.2 Manufacturing Order

5.1.3 Manufacturing Orders Review

5.1.4 Component Check

5.1.5 Print & Release Order

5.1.6 Order Receipt & Issue

5.1.7 Inventory in Process

5.1.8 Order Transactions

5.1.9 Management MaintenanceWhat are the Spare Parts for ?

5.2 Shop Floor Control

5.2.1 Activity Control Report

5.2.2 Shop Floor Transaction Details

6 Distribution Management

6.1 Distribution Management Setup

6.2 Distribution Network

6.3 Freight Category

6.4 Shipper

6.5 Distribution Order

6.6 Generate Movement - Manual

6.7 Generate Movement - Process

6.8 Inventory Move

7 Quality Management

7.1 Quality Specifications

7.2 Bill of Materials & Formula

7.3 Print Test Results

8 Standard Costing Management

8.1 Create Doc Type to Manufacturing

8.2 Create Element

8.3 Product Costing

8.4 Copy Price to Standard Cost

8.5 Workflow Cost Roll-Up

8.6 Cost Workflow & Process Details

8.7 Bill of Material & Formula Cost Roll-Up

8.8 Cost Collector