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MISys Primer

I. MANUFACTURING ORDERS NOTEBOOK

Figure C-2 - Creating Manufacturing Order

Click the New button to create a new order. If the Auto-increment function is enabled for
Manufacturing Orders, MISys will display the next Manufacturing Order number. Otherwise, enter
the number of the order you are creating. Press the Tab key.

Enter a description of the order you are creating.


Click the Priority drop-down box and select an appropriate Priority for this Manufacturing Order.

The Priority function labels a Manufacturing Order, and is used to identify urgent orders in the
Work Center Dispatch List by highlighting them in red, but has no other function in version 4.2A.

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1. HEADER TAB (L2 MANUFACTURING ORDER NOTEBOOK)

Establish the focus on the field labeled Item No. and enter the number of the Item you wish to
assemble with this Manufacturing Order, or use the Finder button to select a valid Item number.

You must select an Item which is identified in the Item Master file as an Assembled Item. You
cannot create a Manufacturing Order for any other type of Item.

Revision The Revision of the assembled Item you wish to build with this order. Use the
Finder button to select a valid Revision number for this Item. Note: The Revision
field does not appear if the BOM Revision option is disabled in the Setup
notebook.
Creator The ID of the person creating this Manufacturing Order. This field defaults to the
ID of the currently logged-in user.
Job No. The Job you wish to associate with this Manufacturing Order. May be left blank if
you do not use Job numbers. Note: The Job No. field does not appear if the Job
Tracking option is disabled in the Setup notebook.
Location The Location from which components will be consumed and the assembled Item
put into stock. If multiple Locations are enabled in the Setup notebook, this is a
required entry. Use the Finder button to select a valid Location code.
Unit Order Qty. The quantity of the assembled Item you wish to build with this Manufacturing
Order. Fractional quantities are allowed (check quantity precision in Setup
notebook). Note: After entering the Unit Order Quantity, the program pauses to
copy the BOM into the Manufacturing Order details.
Order Date The date you wish to create this Manufacturing Order. Defaults to today's date,
but may be set to any date in the past or future.
Start Date The date you expect to start production on this Manufacturing Order.
Completion Date The date you expect to complete production on this Manufacturing
Order.

Dates
If there are no routing details, MISys predicts the Completion Date by adding the Maximum
Lead from the assembled Item's BOM to the Start Date. Modify the default date as needed.
If there are routing details, MISys predicts the Completion Date by using the Queue, Setup,
Run, and Wait times to calculate the time required to process the Manufacturing Order.
There are two Set buttons, one associated with the Start Date and one associated with the
Completion Date, which are functional only if BOM routing details have been entered. One
sets the Completion Date by adding the assembly time to the Start Date. The other sets the
Start Date by subtracting the assembly time from the Completion Date.

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2. NOTES TAB (L2 MANUFACTURING ORDER NOTEBOOK)

Figure C-3 Notes Tab Manufacturing Order

On the Notes tab, enter the following fields:

Optional Text Up to four fields of 30 characters each of text which can be printed anywhere you
wish on the Manufacturing Order.
Sales Order No. Up to 22 characters of the Sales Order you wish to associate with the
Manufacturing Order. If the feed to ACCPAC Order Entry is enabled in the Setup
notebook, the Finder appears so you can select a valid SO number.
Detail Line No. Up to 5 characters of the Sales Order Detail Line number you wish to associate
with the Manufacturing Order. If the feed to ACCPAC Order Entry is enabled in
the Setup notebook, the Finder appears so you can select a valid Detail Line
number.
Document The complete path and filename (with extension) of an attached word processing
document in the Document field.

If you are unsure where your document file is located, use the Browse button. By convention, the
path and filename for ACCPAC documents is d:\PROGRAM
FILES\ACCPAC\COMPANY\company but you can change it to anything you want.

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3. DETAILS TAB (L2 MANUFACTURING ORDER NOTEBOOK)

Figure C-4 Detail Tab (Scrap function) Manufacturing Order

The material details from the assembled Item's BOM have been copied to the Material tab. You
are free to change the details for this particular Manufacturing Order, adding, deleting, or
modifying the details as required.

If you add material details, and you have implemented Level 3, be sure to associate them with
their respective Operations.

In the Manufacturing Order material details container enter the following fields:

Detail Type The type of detail as identified in the assembled Item's BOM.
Standard: A component Item whose quantity depends on the quantity of the Item
being assembled. The quantity consumed is proportional to the quantity
completed.
Comment: A textual entry up to 60 characters in length.
Setup: A component Item whose quantity is independent of the quantity of the Item
being assembled. The quantity is entirely consumed and is not
reversible.
Consumed: A component Item whose quantity is independent of the quantity of the
Item being assembled, but not disassembled. The quantity is entirely
consumed but is reversible.

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Item No. The number of the component Item. When adding details to a Manufacturing
Order, use the Finder button to select a valid Item.
BOM Revision If the material detail is an assembled Item, the Revision of the Item you wish to
use as a component in this Manufacturing Order. Use the Finder button to select
a valid Revision number for this Item. Note: The Revision field does not appear if
the BOM Revision option is disabled in the Setup notebook.
Lead The number of days into the production process when this detail is required (e.g.
tires are not required on the first day of automobile assembly). 0 means it is
needed immediately, 1 means 1 day later, etc.If you have implemented MISys
Level 3 and have entered BOM routing details, the material detail Lead field is
irrelevant and is ignored.
Source Location The Location from where this material detail will be dispensed. Defaults
to the preferred Location for the component Item.
Required Qty. The quantity of the associated Item required by this Manufacturing Order. The
field defaults to a value which is the extension of the assembled Item's BOM, but
may be modified as required.
Child Order The number of another Manufacturing Order to build the specified subassembly.
Any entry here will prevent this detail from being subject to the Auto-build action
for this Manufacturing Order. Use the Finder button to select a valid order. MISys
will display only Manufacturing Orders for the associated Item.
Auto-build Not applicable unless the associated Item is assembled. Then you have the
choice of disabling Auto-build action, or enabling it as specified in the assembled
Item's bill of material. Note: Details with Child orders can never be subject to
Auto-build action.
Comment Up to 60 characters of text you wish to associate with this order detail.
Operation The Operation number from the MO routing detail where this material will first be
needed. DO NOT attempt to make an entry in this field until you have created
Routing details for this Manufacturing Order.

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4. COSTS TAB (L2 MANUFACTURING ORDER NOTEBOOK)

Figure C-5 Costs Tab Manufacturing Order

The introduction of Manufacturing Orders in MISys Level 2 provides a powerful means for
capturing actual manufacturing costs. The Costs tab reveals costs related to the order.

Standard Cost
The first group of costs, labeled Standard, are captured from the parent Items Bill of Material.
They include:

Material The sum of Standard costs derived from the material details of the BOM plus
Material-type Work Center Resources related to the routing details of the BOM.
Labor The sum of Standard costs derived from Labor-type Work Center Resources
related to the routing details of the BOM.
Overhead The sum of Standard costs derived from Overhead-type Work Center Resources
related to the routing details of the BOM.
Assembled The Assembled cost of the Item as indicated in its Bill of Material (the sum of its
Material, Labor, and Overhead cost components).
Standard The Standard cost of the Item as indicated in the Item Master.
Variance The difference between the Standard and Assembled Costs.

Projected Costs

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The second group of costs, labeled Projected, are captured and updated after the Manufacturing
Order is created and up to the time it is released. These include:

Material The sum of Standard costs derived from the material details of this order plus
Material-type Work Center Resources related to the routing details of this order.
This cost may change as the material details and routing details for this order are
modified.
Labor The sum of Standard costs derived from Labor-type Work Center Resources
related to the routing details of this order. This cost may change as the routing
details for this order are modified.
Overhead The sum of Standard costs derived from Overhead-type Work Center Resources
related to the routing details of this order. This cost may change as the routing
details for this order are modified.
Projected The sum of its Material, Labor, and Overhead cost components.
Markup A factor that is used to compute the Quote price from the Projected cost.
Quote The Projected cost multiplied by the Markup factor.

Thus the Projected cost is a measure of what the manufacturing costs should be considering any
order-specific modifications to the details. The Projected cost is frozen at the instant the order is
released. Any subsequent changes to the Manufacturing Order will not affect the Projected cost.
The variance of Projected to Standard gives a good indication of the magnitude of changes made
to the order.

Used Cost
However, changes do occur to Manufacturing Orders after they have been released. Additional
material may be required, some material may not be needed after all, and some material may be
scrapped. All these contribute to the Used cost of the order, that is, the cost of the order based on
the material used to complete it. The program displays these costs in the container column
labeled Used including:

Material The sum of Standard costs derived from the material details used to complete
this order, plus Material-type Work Center Resources consumed for this order.
Labor The sum of Standard costs of Labor-type Work Center Resources consumed for
this order.
Overhead The sum of Standard costs of Overhead -type Work Center Resources
consumed for this order.
Completed The sum of the Material, Labor, and Overhead costs required to complete this
Manufacturing Order.
Scrap The accumulated Standard cost of material details scrapped during the
completion of this Manufacturing Order.
Total The sum of the Completed cost and Scrap amount, as an indication of the total
cost of materials and other resources used to complete this order.

Any changes made to the Manufacturing Order after it is released, affect the Used cost. Thus in-
production changes (overruns, under-runs, and scrap) have the affect of driving up (or down) the
Used cost of the Manufacturing Order. The variance of Used to Projected gives a good indication
of the "manufacturing efficiency" you experience.

Actual Cost
If you are using the Shop Operations function of MISys to track the work you perform on a
Manufacturing Order, in addition to recording the materials used, the program will record the
actual time required to complete each Operation. The Shop Operation entries you make drive the
Actual column of the Manufacturing Order cost container. This column includes the following
costs:

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Material The sum of Standard costs derived from Shop Operations completed for this
order which are related to material details and Material-type Work Center
Resources.
Labor The sum of Standard costs derived from the actual time logged in Shop
Operations completed for this order which are related to Labor-type Work Center
Resources.
Overhead The sum of Standard costs derived from the actual time logged in Shop
Operations completed for this order which are related to Overhead -type Work
Center Resources.
Completed The sum of the Material, Labor, and Overhead costs derived from Shop
Operations required to complete this Manufacturing Order.
Scrap The accumulated Standard cost of material details derived from material
scrapped in Shop Operations during the completion of this Manufacturing Order.
Total The sum of the Completed cost and Scrap amount, as an indication of the actual
cost of materials and other resources used to complete this order.

Over the long term, an analysis of the variance of Actual to Projected for an entire range of
Manufacturing Orders (or the Manufacturing Orders related to a specific Job) can yield valuable
cost efficiency information which can be used to improve your quoting methods (i.e. if you always
seem to run 20% over, a higher markup factor may be indicated). See the MO Cost Comparison
Report (MI639025).
The ultimate value of the MISys Manufacturing System lies in its ability to enhance your
company's profitability.

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5. ROUTING TAB (L3 MANUFACTURING ORDER NOTEBOOK)

Figure C-6 Routing Tab Manufacturing Orders

Click the Routing tab to view the routing details inherited from the parent Items Bill of Material.
You are free to change the details for this particular Manufacturing Order, adding, deleting, or
modifying the details as required.

If you add routing details, be sure to return to the Material tab to associate needed material
details with their respective Operations.

In the Manufacturing Order routing details container enter the following fields:

Operation Number A sequence number assigned and maintained by the program to


uniquely identify each Operation in the routing details. Cannot be edited.
Milestone Yes, if the selected Operation must be completed before the following Operation
is started. No, if the selected Operation can be performed in any order prior to
the next milestone Operation.
Work Center The Work Center associated with the selected Operation.
Batch Size The quantity of the parent Item you can process in the selected Work Center as
one batch. This number is used to determine how the Setup time contributes to
the quantity being built. If you leave the Batch Size 0.0, the program will apply
the Setup each time the Item is built regardless of quantity.

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Unit Run The number of minutes required to process one (1.0) of the parent Item at the
specified Work Center. This entry defaults to the Unit Run established in the
parent Items Bill of Material.
Extended Run The number of hours required to process the Order Quantity.
Setup The number of minutes required to set up a batch of this Work Center for this
particular Operation. This entry defaults to the Setup time established in the
parent Items Bill of Material.

Queue The number of minutes the material will be queued at this Work Center for this
particular Operation. This entry defaults to the Queue time established in the
parent Items Bill of Material.
Wait The number of minutes the material will wait at this Work Center after this
particular Operation. This entry defaults to the Wait time established in the parent
Items Bill of Material.

Click the Overlap field or use the spacebar key to toggle the Yes/No selection. Setting this field to
Yes indicates that the selected Operation can proceed as soon as a sufficient
quantity has been completed in the previous Operation.

The setting of the Overlap switch has no affect on the first Operation.

Tab from field to field making the following entries:

Tool No. The Tool that you need to complete the selected Operation. Use the Finder to
select from a list of valid Tools from the Tool Master file.
Comment Up to 60 characters of text you want to associate with this MO routing detail.

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6. BILL OF MANUFACTURING TAB (L3 MO NOTEBOOK)

Figure C-7 Bill of Manufacturing Tab Manufacturing Orders

Return to the material details of this Manufacturing Order by clicking the Material tab. Click the
right side of the horizontal scroll bar to reveal the Operation field. Check to be sure that each
material detail is associated with an Operation.

Leaving the Operation field of a material detail blank is not necessarily a mistake and will not
cause the program any concern. By convention, any material detail without a specified Operation
is assumed to be used in the last Operation. Nonetheless, a missing Operation may indicate an
oversight in setting up material details for this Manufacturing Order, so such an entry is
highlighted in red on the Bill of Mfg. tab.

When you are done, click the Bill of Mfg. tab to examine the Bill of Manufacturing for this
Manufacturing Order. (Alternatively, you can click File | Print on the menu bar, then select a Bill of
Manufacturing report for this Manufacturing Order.) Confirm that the Bill of Manufacturing
accurately lists the Operations in the proper order and the materials required for each Operation.

Materials associated with Work Center Resources are displayed with a yellow highlight and
appear after the materials associated with the Operation in the Materials tab. Material details with
no associated Operation appear last and are highlighted in red.

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7. RELEASING THE MO (L2 MO NOTEBOOK)

Figure C-8 Releasing a Manufacturing Order

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II. WORK CALENDAR (L2 MO NOTEBOOK)

Figure C-9 Work Calendar

For any given date, you can indicate whether the day is a workday or holiday. MISys uses this
information when it schedules your production activities. The Work Calendar does not affect your
purchasing activities.

The entries you make in the Work Calendar, whether workdays or holidays, have the effect of
overriding the holidays you identify in the Schedule Setup function.

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III. SCHEDULE SETUP

1. PERIOD TAB (L2 SCHEDULE SETUP NOTEBOOK)

Figure C-10 MPS Period Tab

Click the New button, then enter the 3-character ID of the schedule you wish to create. In the
Description field, enter any text which will adequately describe this Master
Schedule.

If you wish to modify an existing Schedule Setup, enter the ID of that Schedule, or click the Finder
button and select a valid Schedule Setup. If you select an initialized Master
Schedule, then you may only modify its description and attached document.

The Periods tab of the Schedule Setup notebook will be displayed. In the Periods option box,
click:

Days To have each period span between 1 and 99 days.


Months To have each period span between 1 and 99 months.

In the Period Length field, enter the number of days or months you wish each period to represent.

If you wish to schedule week-by-week, you should specify Days, then a Period Length of 7.

In the Period Count field, enter the number of periods you wish your schedule to span (from 1 to
96).

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In the Start Date field, enter the date you would like this Master Schedule to begin. The program
defaults this field to the first day of the current month. The End Date is displayed
based on the Period Count and Period Length you have previously specified.
In the Period Definition option box, you may specify a different End Date for a selected period.
The Start Date of any period is the day after the End Date of the previous period.
The number of Workdays in the selected period is displayed for your information.

You should specify a Period Definition only if you wish to employ periods of unequal length.
Usually, setting the Period Length parameter is sufficient to establish periods of
equal length.

In the Holidays option box, check the days of the week you normally consider to be plant holidays
(e.g. Saturday and Sunday). MISys will not schedule any production activity on
these days unless they are otherwise indicated as Workdays in the Work
Calendar.

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2. CRITERIA TAB FOR MFG (L2 SCHEDULE SETUP NOTEBOOK)

Figure C-11 Schedule Setup for MFG

In the Initialization option box, enter the ID of the Location for which you wish to create this
Master Production Schedule, or use the Finder button to select a valid MISys
Location.

You may click the All checkbox to create a Schedule for all Locations. However, initializing a
Master Schedule in this mode takes more time and creates a larger database.

Next select the Auto-build Override mode you wish to use during initialization.
Unless you are sure you want the Master Schedule initialization to be affected by the Auto-build
action, make sure you select Never.

Click the Shortage Basis drop-down box and select:

Zero To consider that a shortage exists when Stock falls below zero.
Minimum To consider that a shortage exists when Stock falls below the Minimum
established in the Item Master.
Reorder To consider that a shortage exists when Stock falls below the Reorder point
established in the Item Master.

Proceed to check the following checkboxes:

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Include Current Stock To include in the Master Schedule material currently in Stock and WIP.
If you clear this checkbox, MISys will ignore current Stock and WIP. Doing so would only be
appropriate if you were creating a Master Schedule for some time in the
considerable future.
Include Current Activity To include currently open Purchase Orders and Manufacturing Orders in
the Master Schedule.
If you clear this checkbox, MISys will ignore current orders. Doing so would only be appropriate if
you were creating a Master Schedule for some time in the considerable future.
Use Work Calendar To have the program honor the entries made in the MISys Work
Calendar. MISys will not schedule production for days you have indicated are
holidays. The Work Calendar will not affect purchasing.
Optimistic Scheduling To consider Stock that is scheduled to become available in the middle of
a period to be available for the entire period. If you clear the Use Optimistic
Scheduling checkbox, you are asking the program to be pessimistic. Specifically,
Stock that is scheduled to be received in the middle of a period will not be
available until the next period.
Maintain Audit List To have the program keep a record of all current activity and scheduled
activity in the Master Schedule. This option is particularly helpful when you are
learning about MISys Level 2 and developing confidence in the program's
scheduling algorithms. There is some increase in disk space consumed and
decrease in performance, so you may wish to run with this option disabled unless
you are trying to resolve a scheduling problem
Alternative Locations To have MISys consider any stock available in the Alternative Locations
you have established.If you wish to use this option, you must first establish
Alternative Locations. Click here to review the basics of Locations.
Include Sales Stock To include any available stock in the ACCPAC [sales] Inventory.
Include Sales Orders To include qualifying sales orders in the ACCPAC Order Entry system.
To use this feature, the ACCPAC I/C [sales] Location must be mapped to a MISys Location in the
Location Master. Only incomplete order details for Active, Standing and Future
orders will be included. Sales Orders do not qualify unless there is a
corresponding Item number in the MISys Item Master, and there is no other
Manufacturing Order associated with this Sales Order Detail.

In the Document option box, specify the full path and file name for the document you wish to
attach to this Master Schedule. If you don't remember the full path and file name,
click the Browse button to select a valid filename.

The attached Document is entirely optional but serves as a convenient means for recording notes
to yourself about the purpose of a Master Schedule, or for communicating to
other users information about the work you have performed.

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3. FILTER TAB FOR MFG (L2 SCHEDULE SETUP NOTEBOOK)

Figure C-12 Schedule Setup Filter Tab

When setting up a new Master Production Schedule, use the Filter tab to set up the default filter
which determine which Items are displayed in the Master Schedule Item Summary window.
Items are displayed in the Master Schedule Item Summary if they meet a defined set of criteria
related to Current Activity, Scheduled Activity, and the current Stock Level.

If you wish to create a criteria that includes Current Activity, click the Current Activity drop-down
box and select:

Ignore To include an Item in the Master Schedule Item Summary display regardless of
its Current Activity.
Must Have To include an Item in the Master Schedule Item Summary display if it does have
Current Activity. Exclude it if it does not have Current Activity regardless of any
Scheduled Activity or its stock levels.
May Have To include an Item in the Master Schedule Item Summary display if it does have
Current Activity. Do not exclude the Item if it does not have Current Activity.

May Not Have To include an Item in the Master Schedule Item Summary display if it does not
have Current Activity. Do not exclude the Item if it does have Current Activity.
Must Not Have To include an Item in the Master Schedule Item Summary display if it does not
have Current Activity. Exclude it if it does have Current Activity regardless of any
Scheduled Activity or its stock levels.

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If you wish to create a criteria that includes Scheduled Activity, click the Scheduled Activity drop-
down box and select:

Ignore To include an Item in the Master Schedule Item Summary display regardless of
its Scheduled Activity.
Must Have To include an Item in the Master Schedule Item Summary display if it does have
Scheduled Activity. Exclude it if it does not have Scheduled Activity regardless of
any Current Activity.
May Have To include an Item in the Master Schedule Item Summary display if it does have
Scheduled Activity. Do not exclude the Item if it does not have Scheduled
Activity.

May Not Have To include an Item in the Master Schedule Item Summary display if it does not
have Scheduled Activity. Do not exclude the Item if it does have Scheduled
Activity.
Must Not Have To include an Item in the Master Schedule Item Summary display if it does not
have Scheduled Activity. Exclude it if it does have Scheduled Activity regardless
of any Current Activity.

If you wish to create a criteria that includes Stock Level, click the Stock Level drop-down box and
select:

Ignore To include an Item in the Master Schedule Item Summary display regardless of
its Stock Level.
Must Have To include an Item in the Master Schedule Item Summary display if its Stock
Level matches the one selected. Exclude it if it does not match the one selected
regardless of any Current or Scheduled Activity or its stock levels.
May Have To include an Item in the Master Schedule Item Summary display if its Stock
Level matches the one selected. Do not exclude the Item if it does not have the
specified Current or Scheduled Activity.

May Not Have To include an Item in the Master Schedule Item Summary display if its Stock
Level does not match the one selected. Do not exclude the Item if it has the
specified Current or Scheduled Activity.
Must Not Have To include an Item in the Master Schedule Item Summary display if its Stock
Level does not match the one selected. Exclude it if it does match the one
selected regardless of any Current or Scheduled Activity or its stock levels.

If you have selected a Stock Level other than Ignore, click the next drop-down box and select:

Less than 0 Quantity in stock less than 0 (negative stock).


Less than Minimum Quantity in stock below the Minimum stock level.
Less than Reorder Quantity in stock below the Reorder point.
Less than Maximum Quantity in stock below the Maximum stock level.
More than Maximum Quantity in stock above the Maximum (excess stock).

When determining which Items should be displayed in the Master Schedule Item Summary,
MISys considers your selection for Current Activity, Scheduled Activity, and Stock Level as a
logical expression which yields a True or False result. This expression is displayed in textual form
in the box to the right of the drop-down lists. If the expression is True, the Item is displayed,
otherwise it is not displayed.
In the Item Types option box, check an Item Type checkbox to include in the Master Schedule
Item Summary:

Raw Materials Items which are so identified in the Item Master file.

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Final Assemblies Items which are identified as Assembled in the Item Master file and
which are not used in higher level assemblies.
Sub-assemblies Items which are identified as Assembled in the Item Master file and which are
used in higher level assemblies.
Resources Items which are so identified in the Item Master file.
Bulk Issue Items which are so identified in the Item Master file.

Outside Processing Items which are so identified in the Item Master file.

In the Location field enter the number of the Location for which you wish to display Items in the
Master Schedule Item Summary, or use the Finder button to select a valid Location. Check the All
checkbox to display Items for all possible Locations.

Selecting a specific Location (or All Locations) will have no effect unless the Schedule is being
initialized for that that specific Location or all Locations.

Since entries you make in the Master Schedule can change the status of an Item, causing an
Item which was formerly qualified to appear in the Master Schedule Item Summary display to no
longer be qualified, you are given the option of retaining (or not retaining) on the display those
Items which are no longer qualified. Clear the "Retain disqualified" checkbox if you do not want
disqualified Items to appear.
After making changes to the default Master Schedule filters, click the Setup button to save your
changes to the filter and return to the Master Schedule Setup window.

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D. MISys Level 3

Objectives for MISys Level 3


Master Files Work Center
Tool
Calendar
How to Create a Work Center
Create a Tool
Run a dispatch list
Produce a Traveler
Record progress on a Manufacturing Order (Time and Material)
How to run the Shop Operation Reports
Concepts Shifts
Material, Labour, and Overhead
Capacity

Why Shop Operations?

With the advent of MISys Level 3, it is much easier to track Shop Floor transactions and
gather reliable data regarding the actual status and performance of your Production
Department and the costs involved.
Implementing an effective Shop Floor Control system using MISys requires considerable
commitment and discipline on the part of your management and production staff.
Even the simplest of manufacturing inventory systems require more effort than just walking
into the stockroom and taking whatever it is you need.
Tracking Shop Operations requires much more commitment you must painstakingly record
each step of the production process, counting the material actually used, accounting for
material spoiled and scrapped, and recording the actual time spent in production. However,
the reward for your efforts is great.
There is no better way to gain control of your production activities and insure the profitability
of your manufacturing operation.
The Shop Operations function of MISys has been designed to ease the entry of this data,
requiring a minimum number of keystrokes to record the required data accurately.
Nonetheless, developing shop procedures to use this function effectively requires that you
develop procedures that everyone in your Production Department will be willing and able to
follow.
The MISys Shop Floor Control system requires that you adopt a strict commitment to
following the Milestones and Operations documented in each manufacturing Order. These
Milestones must be completed in sequence (although Operations within Milestones may be
completed in any order) and the materials and time consumed in each must be reported
accurately.

Start
Starting from the moment a Manufacturing Order is first moved into production, you use the Shop
Operations function of the Production desktop to record a start of the first Operation. This
moves the related material from Stock into WIP and updates the Manufacturing Order
accordingly. We recommend that you record the name of the responsible operator for each entry
since this information is recorded in the perpetual history maintained in the Master Transaction
Log.

Complete
When the first Operation is completed, you return to the Shop Operations function to record a
complete. When you do, MISys also asks for the amount of time (expressed in hours or

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minutes) it took you to complete the Operation. It does this to update the Manufacturing Order
with the actual time and cost for the production you have completed.
As production moves from Operation to Operation, you can use the Shop Operations function to
start and complete each Operation in sequence. It is not necessary that you explicitly start each
Operation. Completing an Operation which has not been started forces the program to execute
an implied start. For this reason, you need only enter the completion of each Operation.

Following this procedure allows you to check on the status of any Manufacturing Order in your
plant and check on the Location and quantities of the related components.

Using Milestones
Milestones are identified as such in the Routing tab of a Bill of Material or Manufacturing
Order.
Milestones must be started and completed in strict order, although previous intermediate
Operations can be completed in any order.
Starting or completing a Milestone implies that all previous intermediate Operations have
been completed. Starting or completing the last Milestone requires that all previous
Milestones have been completed.
Milestones can be used effectively to enforce a sequence of Operations which must be
followed in order.
If there are intermediate Operations that can be performed in any order (within a Milestone)
then these Operations should not be identified as Milestones. If all the Operations can be
completed in any order, then none of them should be Milestones.

Overlapping Operations

If you have enabled the Overlap option in the Routing details of the Manufacturing Order, the
program will allow you to start (either explicitly or implicitly) an Operation even if its preceding
Operation has not been completed. However, the program is quite strict about enforcing the
requirement that you complete sufficient material in one Operation before allowing the next
Operation to proceed.
As work progresses from the first Operation towards the last, required material is moved from
Stock to WIP. However, accumulated WIP is not dispensed until the last Operation is
completed.
Overlaps are automatically calculated to insure that the second Operation never out-runs the
first Operation. That is, the second Operation is not started until there is sufficient output from
the first Operation to guarantee that the second Operation not have to be stop due to lack of
output from the first.

Scrap
The Scrap transaction of the Shop Operations function provides a means for writing-off material
that has been spoiled in the production process. You entry here has an immediate impact on your
inventory by performing a writeoff transaction and reducing the inventory of the indicated Item. At
the same time, scrapping material against an Operation drives the Scrap cost bucket of the
Manufacturing Order, increasing the cost of the Order and reducing the profitability as reported on
the MO Cost tab or by the MO Cost Comparison Report (MI639025).

The Shop Operations function also offers a facility for recording time against a specific Operation.
This can be used if you forget to include time in a normal complete transaction, or wish to log
additional time against any Operation. The result of your entry will be to increase the actual time
spent in production as recorded on the Manufacturing Order, and ultimately the actual cost
reported on the MO Cost tab or by the MO Cost Comparison Report (MI639025).

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MISys Primer

I. WORK CENTERS NOTEBOOK

1. HEADER TAB (L3 WORK CENTER NOTEBOOK)

Figure D-1 Work Center Header Tab

Enter up to 12 alpha-numeric characters which will uniquely identify this Work Center.
Description The description you wish to use for this Work Center.
Cycle time The typical number of minutes required to process one (1) unit at this Work
Center. This value is approximate and is used as the default when Bill of Material
and Manufacturing Order routing details are created.
Setup time The typical number of minutes required to set up this Work Center prior to
processing any number of units. This value is approximate and is used as the
default when Bill of Material and Manufacturing Order routing details are created.
Queue time The typical number of minutes required to wait before this Work Center is
capable of processing any number of units. This value is approximate and is
used as the default when Bill of Material and Manufacturing Order routing details
are created.
Wait Time The typical number of minutes required to wait after this Work Center has
processed any number of units. This value is approximate and is used as the
default when Bill of Materials and Manufacturing Order routing details are
created.

Document The path and filename of a document associated with this Work Center or use
the Browse button to help locate the filename.
Efficiency The average efficiency of this Work Center (for reference only, not used in
version 4.2A).

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MISys Primer

2. SHIFTS TAB (L3 WORK CENTER NOTEBOOK)

Figure D-2 Work Center Shifts Tab

When adding a Work Center, the shift information is automatically entered from the system
defaults. To establish a new default, make the appropriate shift entries, then click the button
labeled Save as Default.

To delete a Shift detail entry, click to select it, then press the Del key. When the dialog box
appears, click Yes to confirm your intention.
To insert a Shift detail entry, click to establish the focus in the shift container, then press the Ins
key.

MISys can accommodate an unlimited number of Work Center shift details, so virtually any
environment of full-time, part-time, and split shifts can be described.

Enter or modify the following shift detail information:

Type Click the drop-down arrow to select either Standard or Optional.


Standard shifts are available as a normal part of your plants work week.
Optional shifts are available only if specifically requested (e.g. overtime).
Start time The time (expressed in 24-hour format) when the selected shift starts operation.
Stop time The time (expressed in 24-hour format) when the selected shift stops operation.
Off time The number of hours and minutes (expressed as hh:mm) when the selected shift
has ceased operation (e.g. lunch break).
Sun Click Yes to indicate that the selected shift operates on Sundays.

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MISys Primer

Mon Click Yes to indicate that the selected shift operates on Mondays.
Tue Click Yes to indicate that the selected shift operates on Tuesdays.
Wed Click Yes to indicate that the selected shift operates on Wednesdays.
Thu Click Yes to indicate that the selected shift operates on Thursdays.
Fri Click Yes to indicate that the selected shift operates on Fridays.
Sat Click Yes to indicate that the selected shift operates on Saturdays.

Specific workdays and holidays recorded in the Work Calendar override Work Center shifts.
Description A description of the selected shift detail.

When you have entered a shift detail, the program displays:


Total time The total time (expressed in hours and minutes as hh:mm) when the
selected shift is in operation each week.
Standard The total time (expressed in hours and minutes as hh:mm) available from
Standard shifts of the selected Work Center each week.
Optional The total time (expressed in hours and minutes as hh:mm) available from
Optional shifts of the selected Work Center each week.
Total The total time (expressed in hours and minutes as hh:mm) available from
Standard and Optional shifts of the selected Work Center each week.

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MISys Primer

3. RESOURCES TAB (L3 WORK CENTER NOTEBOOK)

Figure D-3 Work Center Resources Tab

To delete a Resource entry, click to select it, then press the Del key. When the dialog box
appears, click Yes to confirm your intention.
To insert a Resource entry, click to establish the focus in the Resource container, then press the
Ins key.

MISys can accommodate an unlimited number of Work Center Resources.

Enter the following Resource information:

Type Click the drop-down arrow to select Material, Labor, or Overhead.


Material resources are inventoried Items which are consumed in the
manufacturing process in the selected Work Center. The cost of material
resources is derived from the standard cost of the Item(s) and, ultimately, adds to
the material cost of the Item being produced in this Work Center.
Labor resources are Resource-type or Outside processing-type Items which are
consumed in the manufacturing process in the selected Work Center. The cost of
labor resources is derived from the standard cost of the Item(s), is used to
calculate the Work Centers Labor Rate and, ultimately, adds to the labor cost of
the Item being produced in this Work Center.
Overhead resources are Resource-type or Outside processing-type Items which are consumed in
the manufacturing process in the selected Work Center. The cost of overhead

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MISys Primer

resources is derived from the standard cost of the Item(s), is used to calculate
the Work Centers Overhead Cost and, ultimately, adds to the overhead cost of
the Item being produced in this Work Center.
Item The number of the Item associate with this Work Center Resource. Limited to
Resource-type Items for Labor and Overhead Work Center Resources. Click the
Finder button to select a valid Item.
Quantity per Hour The quantity of the specified Item consumed in each hour of the Work
Centers operation. No entry is allowed if a Quantity per Unit is specified.
Quantity per Unit The quantity of the specified Item consumed for each unit produced in
the selected Work Center. No entry is allowed if a Quantity per Hour is specified.
PO Number The number of the Purchase Order on which a Outside processing-type Item
appears as the selected Work Center Resource. Click the Finder button to select
a valid Purchase Order.
Comment Any text to describe this resource.

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MISys Primer

4. INQUIRY TAB (L3 WORK CENTER NOTEBOOK)

Figure D-4 Work Center Inquiry Tab

Load Graph A graph showing the available capacity of this Work Center and the loads placed
upon it by open Manufacturing Orders for a specific range of dates.
Dispatch List A list of Manufacturing Orders due to be processed in this Work Center, selected
and sorted by ascending date.
BOM Where Used A list of Bills of Material in which this Work Center is used.
MO Where Used A list of Manufacturing Orders in which this Work Center is used.

How to Run the Load Graph


In the fields labeled Start Date and End Date, enter the dates you wish the Load Graph to
encompass.
Then click:
Include Optional Shifts To include Optional Shifts for this Work Center, making
additional time available, increasing Work Center capacity, and potentially
avoiding overloads.
Overlap Operations To allow Work Center operations which can be overlapped to
overlap previous operations, which may shorten production times but overextend
Work Center capacity and produce overloads.
Exclude Non-work Days To disable the display of dates which are identified as non-
workdays in the Work Center shift record or as holidays in the Work Calendar.

After entering a range of dates and selecting the options described above, click the green Go
button. The Load Graph will soon appear, showing capacity utilization for the selected Work

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MISys Primer

Center for the selected range of dates. If the entire date range is not displayed, click or drag the
horizontal scroll bar to view more of the graph.
The Key to the Load Graph floats and can be dragged to a more convenient location.
The graph illustrates:

Available With green bars showing Work Center capacity that is unused and available for
any given day.
Used With blue bars showing Work Center capacity that is used for open
Manufacturing Orders.
Over With red bars showing Work Center capacity overload because of open
Manufacturing Orders.
Optional With yellow lines showing Work Center capacity resulting from Optional Shifts
that is Available or Used.

To print a copy of the Work Center Load Graph, click the Print button.
The Work Center Load Graph has a drill-down function to show the Manufacturing Orders which
contribute to Work Center utilization. Click on any bar to view the Work Center Dispatch List for
the selected day.

Substitute Function:
A window will open listing all the Work Centers available for substitution. Click to select a
Work Center then click the Select button.
A dialog window will appear asking if you wish to substitute the Work Center you just selected
in all Bills of Material and Manufacturing Orders. Click Yes to proceed, No to cancel.
When you have substituted this Work Center, click the Close button to close the Work Center
notebook and return to the Master Files desktop.

Update Routings Function


Click the Update Routings button. A window will appear allowing you to specify the Work
Center times you wish to update for a specific range of BOMs and MOs.
Enter the range of Item numbers you wish to affect. Only Bills of Material for these Items
and/or Manufacturing Orders for these Items will be affected.
A dialog window will appear asking if you wish to update the selected Bills of Material and
Manufacturing Orders. Click Yes to proceed, No to cancel.

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MISys Primer

II. TOOLS NOTEBOOK

Figure D-5 Tools Notebook Tool Tab

Tool No. The number you wish to use to identify this Tool, up to 6 alpha-numeric
characters.
Description The description you use for the selected Tool, up to 30 characters.

If the maintenance/replacement of the selected Tool is use-based, make the following entries In
the Operation Cycles option group:

Already Used The number of cycles the selected Tool has already been used since it was last
maintained or replaced. Unless you have been keeping track manually, you can
leave this set to 0 and allow the program to start counting from there.
Maintenance Due At The number of cycles at which maintenance is required on the selected
Tool.
Replacement Due At The number of cycles at which the selected Tool needs replacement.

If the maintenance/replacement of the selected Tool is date-based, make the following entries:

Maintenance Due The date on which maintenance is required on the selected Tool.
Replacement Due The date on which the selected Tool needs replacement.

If the maintenance/replacement of the selected Tool is both use-based and date-based, it is


acceptable to make entries in all fields.

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MISys Primer

In the Item No. field, optionally enter the number of the Item corresponding to this Tool, or use the
Finder to select a valid Item number. When the Tool is replaced, MISys will automatically
dispense one of these Items.
In the Document field, enter the path and filename of a document associated with this Tool, or
use the Browse button to help locate the filename.

Replace Tool
Replace an existing Tool in your MISys database.

When the Tools window appears, do one of the following to select the Tool you wish to replace:
Enter the code of the Tool in the Tool No. field.
Click the Finder button and select the Tool from the Finder list.
Click the Next and Previous buttons until you locate the Tool you wish to replace.
Click the Replace button.

When the dialog box appears, click Yes to reset Tool statistics and dispense one (1) of the
indicated Items.
Unless you have specified a valid Item number, the Replace button will be de-activated.
If the Multi-location option has been enabled in the Setup notebook, the Finder will appear with a
list of valid Location IDs. Select a valid Location from which to dispense the Item.
Note that the Already Used field is reset to zero (0).
The Already Used field can always be reset to zero (0) manually if you do not wish to dispense
one of the indicated Items.

Substitute Tools
Substitute existing Tools identified in Bills of Material routings and Manufacturing Order routings
in your MISys database.

When the Tools window appears, do one of the following to select the Tool you wish to have
substituted:
Enter the code of the Tool in the Tool No. field.
Click the Finder button and select the Tool from the Finder list.
Click the Next and Previous buttons until you locate the Tool you wish to have substituted.

Click the Substitute button to view a list of available Tools.


Select the Tool you wish to substitute for this Tool.
When the dialog box appears, click OK to confirm your intention.
Click OK to acknowledge that the indicated substitution has been made in all Bills of Material and
all Manufacturing Orders.

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MISys Primer

III. SHOP OPERATIONS

Figure D-6 Shop Operations

After selecting a Manufacturing Order and Operation, there are five functions you can perform
from this window:

Start Starts the selected Operation, moving all related material from Stock to WIP. You
can only Start an Operation if sufficient material was Completed in a previous
Operation.
Complete Completes the selected Operation. If you attempt to Complete a larger quantity
than was Started, the program will automatically Start the required quantity.
When Completing an Operation, the program will record the amount of time (in
minutes or hours) required to complete the Operation. This information will be
used in the computation of actual production costs. When Completing the last
Operation, MISys will move all material from WIP to Stock. If the Completed
quantity exceeds the quantity Started, MISys will draw additional material from
Stock. If the Started quantity exceeds the quantity Completed, MISys will leave
residual material in WIP, but this will automatically be returned to Stock when the
Manufacturing Order is closed.
Time Records pure time (in minutes or hours) against an Operation. This information
will be used in the computation of actual production costs.
Scrap Component Writes-off the specified component Item used in the selected Operation.
This information will be used in the computation of actual production costs.
Scrap Assembly Writes-off the specified assembled Item produced in the selected
Operation.

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MISys Primer

Stock transfers associated the Shop Operations are direct and have an immediate affect on the
inventory status of any related Item(s).

Outside Operations
If any Shop Operation involves Work Center Resources which are currently on an open Purchase
Order, and if that Purchase Order is identified in the Work Center record, then the program will
relieve that Purchase Order each time the Operation is performed. This happens automatically,
beginning with the first occurrence of the Item on the Purchase Order until the quantity on order
has been received in its entirely. Then it proceeds to the next occurrence of the Item on the
Purchase Order until, and so on, until all occurrences of the Item on the Purchase Order have
been received. At that point, performing such a Shop Operation will cause the Work Center
Resource to be dispensed from Stock with no further affect on the referenced Purchase Order.

CA Plus D-36 printed Sep 07, 2014

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