Skip to end of metadata
Go to start of metadata

Advanced Repetitive

Repetitive schedules perform the same functions as work orders in a process environment. This chapter discusses how repetitive schedules are created and exploded, and how inventory is issued when the process is complete.

Introduction 
Outlines the Repetitive and Advanced Repetitive modules and their unique features.

Setting Up Advanced Repetitive 
Defines the basic data and program settings that must be in place to run Advanced Repetitive.

Simulating Schedules in the Workbench 
Describes when and how to set up simulated schedules using Line Schedule Workbench.

Creating Repetitive Schedules 
Defines a repetitive schedule and describes how to update and maintain it.

Exploding Repetitive Schedules 
Defines exploding a schedule and explains how and why to do so.

Using Repetitive Picklists 
Describes why repetitive picklists are used, how to calculate and print them, and how to transfer inventory if necessary.

Managing Cumulative Orders 
Describes how to create, close, and maintain cumulative orders.

Executing Repetitive Transactions 
Describes when repetitive transaction programs are used and how they relate to shipping documents, transaction data, rate variances, and method change variances.

Generating Repetitive Reports 
Describes different kinds of repetitive reports.

Managing Subcontracting 
Describes how to set up subcontract data, operations, and other functions in Advanced Repetitive.

Working with Planning and Scheduling Workbenches 
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.

Introduction

Repetitive manufacturing is executed with schedules rather than work orders. Schedules require fewer steps and less paperwork to execute and are typical in manufacturing environments that use assembly lines to produce similar products using the same process. Since the same activities are repeated regularly, there is little variation.
Repetitive scheduling enables you to:

  • 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

You can use one of two ways to manage repetitive production, appropriate in different business environments. The Repetitive module works well when one or more of the following is true:

  • 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

Advanced Repetitive provides features that are not available in the basic Repetitive module.
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.
Subcontract Processing

  • 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.

Also, the system automatically populates the subcontract operation on subcontract purchase order lines. Therefore, you do not have to return to Purchase Order Maintenance programs to enter the work order ID and subcontract operation.

  • 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.

 

Scheduling

  • In Advanced Repetitive, the earliest open schedule is always consumed—not just completions over the scheduled quantity for that date.
  • Cumulative Completed Maintenance (18.22.2.6) 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 (18.22.2.4) and MRP programs. This prevents overplanning for components that might result from not including WIP.
  • Schedule Delete (18.22.2.7) 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.

  • No labels