Outlines the Repetitive and Advanced Repetitive modules and their unique features.
Defines the basic data and program settings that must be in place to run Advanced Repetitive.
Describes when and how to set up simulated schedules using Line Schedule Workbench.
Defines a repetitive schedule and describes how to update and maintain it.
Defines exploding a schedule and explains how and why to do so.
Describes why repetitive picklists are used, how to calculate and print them, and how to transfer inventory if necessary.
Describes how to create, close, and maintain cumulative orders.
Describes when repetitive transaction programs are used and how they relate to shipping documents, transaction data, rate variances, and method change variances.
Describes different kinds of repetitive reports.
Describes how to set up subcontract data, operations, and other functions in Advanced Repetitive.
Describes the .NET UI-only Planning and Scheduling Workbenches, provides information to find user information for the workbenches, and describes setup programs in QAD EE for the workbenches.
- Build to a repetitive schedule.
- Run a production line without finite schedules.
- Run a production line with repetitive schedules, forward scheduled to capacity limits.
- Report production and let MRP adjust inventory plans.
Advanced Repetitive and Repetitive
- Manufacturing lead times are relatively short and batches do not overlap.
- All work in process is complete by the end of each day.
- Work-in-process (WIP) costs are either insignificant or fairly constant.
- The routing does not include subcontract operations.
The Advanced Repetitive module supports manufacturing environments where the following apply:
- Manufacturing lead times are long.
- Continuous processing is in use; lines are dedicated to one item for days, weeks, or months.
- WIP costs are variable or high.
- Subcontracting operations are managed in a release management (just-in-time) environment.
- Batches can overlap and visibility of and control over WIP are necessary.
Note: The WIP Lot Trace (WLT) module affects some features of the Advanced Repetitive and Repetitive modules. WIP Lot Trace is available as menu option 3.22.13. When activated, additional frames display in some programs. The discussion in this chapter assumes that WLT features are not active. For details, see WIP Lot Trace.
Distinctive Features of Advanced Repetitive
Cumulative Work Order Processing
- Ability to post usage variances without having to close a cumulative order.
- Ability to close a cumulative order and transfer work-in-process (WIP) balances to a new cumulative order for easy phase-in of product structure or routing changes. This also supports accounting period cutoffs.
- Automatic start and end effective date assignment for cumulative order expiration dates.
- Expanded WIP inventory visibility and control.
- Addition of WIP accumulators to track cumulative work moved, rejected, reworked, scrapped, and adjusted.
Scrap, Reject, Rework, and Adjustments Reporting
- Scrap or adjust from either the input, output, or reject queue.
- Record multiple scrap, reject, and rework quantities with reason codes.
- Generate analysis reports, scrap and adjustments usage variance reports, and scrap and adjustments valuation reports.
- Integration of supplier scheduled orders with Advanced Repetitive supports repetitive purchasing of subcontract services. For example, use Backflush Transaction (18.22.13) to optionally backflush components up to the subcontractor operation and create a cumulative work order to track subcontractor activity.
When the system creates the cumulative work order, it assigns a work order ID and automatically updates blank work order ID fields on subcontract order lines with the new ID.
- Subcontract shippers let you create shipment paperwork, register the physical shipment of materials to the subcontractor, and track subcontract activities.
- Using EDI eCommerce to support electronic data interchange (EDI) transactions lets you receive an advance ship notice (ASN) from your supplier to register the receipt of processed materials.
Non‑Milestone Operation Processing
- The Backflush Transaction (18.22.13) and subcontract processing activities let you use non‑milestone backflushing. This replaces the Repetitive Labor Transaction in basic Repetitive.
- Non‑milestone backflushing uses a demand-pull strategy to determine the units needed from non‑milestone operations. The amount depends on the net requirement of the processing milestone operations. The net requirement is satisfied by consuming units in the output and input queues of preceding non‑milestone operations until either the requirement is satisfied or another milestone operation is encountered.
- You can use any repetitive transaction at a non‑milestone operation.
- In Advanced Repetitive, the earliest open schedule is always consumed—not just completions over the scheduled quantity for that date.
- Cumulative Completed Maintenance (220.127.116.11) lets you modify the quantity completed on a repetitive schedule. Changes to a schedule’s cumulative completed are reapplied to the schedule using the consume-earliest-open logic.
- WIP inventory is visible to the Schedule Explosion (18.104.22.168) and MRP programs. This prevents overplanning for components that might result from not including WIP.
- Schedule Delete (22.214.171.124) enables easy deletion of repetitive schedules and their planned work orders. Limit schedule consumption in the past by deleting schedules left open that fall before a specific date. In Schedule Delete, the date defaults to Monday’s date. Use this to establish the earliest open schedule.
Many activities in the two modules are exactly the same or similar. This chapter describes how to use Advanced Repetitive.this topic describes the features of basic Repetitive that differ.