Routing management

This routing code describes the process involved in manufacturing (producing) or processing a product. That is, the sequence of operations and tools that are involved in producing or processing a particular product.

The routing code matches the product code. The product code can be a manufactured product (a bill of materials), or a generic reference to a parent routing which is linked to several products.

Multiple routings can be defined for a single product. Each routing code can be assigned specific management features. These include restriction of the routing to a specific site and to specific areas of functionality (for use in a manufacturing environment, for costing or for capacity planning).

The production site from which the work orders are to be selected.

The production site defined on the user record is displayed by default but can be amended.

Use this field to automatically select the following for this routing:

• If the selected routing is version managed, the version of this routing that applies on the defined date.
• If the selected routing is not version managed, the routing operations with a validity period that span the defined date.

If you leave this field blank and the selected routing is version managed, you can type in the version details to display the applicable date.

Use this field to indicate if this is a major version of this routing. Major versions might be used where there have been increased or significant changes in functionality, that is, the 'form, fit or function' has changed.

If you are creating a new routing and this product code allows routing versions to be managed for it, type in a major version code. You can create any routing version you choose. You are not bound by the versions stored against the stock record. The format of your code, however, must match the format for the sequence number counter defined on the product record.

If you are viewing an existing routing, this field will display the major version of this routing that applies on the defined Reference date.

This field is not available for entry if the product code defined in the Routing field is not version managed.

Use this field to indicate if this is a major version of this routing. Major versions might be used where there have been increased or significant changes in functionality, that is, the 'form, fit or function' has changed.

If you are creating a new routing and this product code allows routing versions to be managed for it, type in a minor version code. You can create any routing version you choose. You are not bound by the versions stored against the stock record. The format of your code, however, must match the format for the sequence number counter defined on the product record.

If you are viewing an existing routing, this field will display (in conjunction with the major version) the minor version of this routing that applies on the defined Reference date.

This field is not available for entry if the product code defined in the Routing field is not version managed.

This field displays a change request ID if this product, or the specific version or revision of this product is associated with an 'active' change request. An active change request is a change request at the planning or implementation stage of the processing cycle. A warning icon is displayed adjacent this field.

If a warning icon is displayed you should consider delaying the creation or amendment of this routing for this product until the change request identified is closed. At that point a change to this product will have either been seen through to its conclusion and the change delivered, or the change request rejected. You will not, however, be prevented from creating or amending this routing should you decide to do so.

Use this field to identify this routing.

Use this field to define the start date of this routing's validity period. Alternatively leave blank if this routing is valid until the defined end date.

Use this field to define the final date of this routing's validity period. If this routing does not have a validity period, or is the current routing, leave blank.

This field indicates the status on the shop floor of the preparation of the operations and tools in this routing. This field will be set to one of the following values:

• 'In development', if the routing is not yet complete.
• 'Available to use', if the routing is complete and the coherence of the routing operations have been validated.

 A routing can only be assigned to the various manufacturing processes (such as work orders and cost calculations) when its status is 'Available to use'.

 The 'In development' and 'Available to use' sites must be identical.

If you are creating a new non-versioned routing you can manually set this field to 'Available to use' when the routing detail is complete. This will also validate the coherence of the routing operations.

If you are creating a new version-managed routing, this field defaults to status 'In development'. Validating the version (using the Validation action) sets this field to 'Available to use' if the coherence of the routing operations is correct.

This field is not available for amendment after the version has been validated, if the routing code defined in the Routing field is version managed.

This field displays the start date of the displayed version's (major and minor) validity period.

This field displays the final date of the displayed version’s validity period. This field is blank if the displayed version is the current, or active version.

Use this field to define how time for the operations in this routing are to be expressed. The time unit can be 'hours' or 'minutes'.

The time you select will apply to the setup time, run time and the rate of all operations in the routing.

Validation of the scheduling grid checks the coherence of the routing operations. For example, it checks the last operation does not have a next operation, the schedule does not loop and at least one production operation has been declared.

If the scheduling is correct, the Compliant flag is checked (set to 'Yes').

If the scheduling is not compliant, several instances must be checked:

• The scheduling details.
• Whether an operation has been added.
• Whether the replacement date of an operation has been modified.
• Whether an operation's replacement date has affected the sequence of operations.
• Whether an operation has been deleted.

Use this field to control amendments to work orders to which this routing is assigned. This includes work order amendments such as replacing work centers, replacing components if there are shortages or changing machinery setup times. You can set this field to one of the following values:

• No change if neither the component nor the operation details can be changed on a work order to which this routing is assigned;
• Materials change if only the components can be changed on a work order to which this routing is assigned;
• Operations change if only the operations can be changed on a work order to which this routing is assigned;
• Change materials and operations if both the components and the operations can be changed on a work order to which this routing is assigned.

Use this field to define a product release quantity range when this routing is applied to a work order. This field represents the minimum quantity (expressed in the stock unit) of the product that must be produced using this routing.

This field displays the unit of measure (volume or mass).

Use this field to define a product release quantity range when this routing is applied to a work order. This field represents the maximum quantity (expressed in the stock unit) of the product that must be produced using this routing.

This field displays the unit of measure (volume or mass).

Date of last release. This date is updated in the routing header for each release of this routing.

This field indicates the actual quantity expressed in the release unit.

This field displays the unit of measure (volume or mass).

Use this field to refer to the workbench or plan used for this routing. This is for information only.

Use this field to refer to the image or plan used for this routing. This is for information only.

Type in the sequence number of this operation.

This field indicates if this operation has been amended. The value displayed concurs with the number of times this operation has been amended. The operation with the highest index number is the new operation.

Use this field to define the start date of this operation's validity period.

If this routing is version managed and you are changing an existing operation (field Index is populated), the default start date is tomorrow.

Use this field to define the final date of this operation's validity period.

If this routing is version managed and you are changing an existing operation, the previous operation (field Index is blank or lower than this operation) defaults to today's date.

Use this field to select a standard operation to simplify the creation of this operation. Standard operations are simply 'template' operations that provide default information to be assembled into routings for producing or processing a particular product. The fields defined in the selected standard operation will provide default values for many of the fields in this operation. Note the following if you confirm 'recovery of the operation data':

• If the operation unit is defined in the standard operation it is applied to this operation.
  If the operation unit is not defined, the stock unit for the product in the routing is applied and converted using the Stock unit-Operation unit conversion coefficient.
• The times (rate, setup time and run time) are converted if the time unit defined in the routing header is different from that defined in the standard operation.
  The standard operation used is referenced by this operation.

 Operations based on a standard operation are not updated if the standard operation is changed.

This field identifies the group of work centers to which this work center belongs. Work center groups are used to review workloads.

This field identifies the type of operation that is performed on the selected work center. This might be a machine, labor or a subcontracted operation. Work centers of type Subcontracting are managed externally by subcontract suppliers.

Use this field to identify the production resource that is to be used for this operation. This work center is the main (principal) work center for this operation.

Type in, or select from the Work Centers table the code of the resource to be used for this operation. It can be a machine, labor or subcontract work center. The scheduling of the operations looks at the availability of this work center. You can specify the number of operators to allocate to it however you cannot allocate more resources than that defined on the work center record.

If you define a work center of type 'subcontracting', the Subcontract code (field SCOCOD) is set to 'Structural' and the operation is automatically subcontracted. The subcontract operations are managed using the lead time defined in the subcontract product record. Subcontract operation times are not used by the scheduling.

To generate a temporary (or ad hoc) subcontract operation enter an internal work center as the main work center and the subcontract work center using a temporary subcontracting code. During the creation of a work order scheduling is carried out by priority on the main (workshop) work center. You can replace this work center with the subcontract work center if the operation is subsequently subcontracted.

This field displays the description defined for the routing operation.

Use this field to define the number for this particular production resource that are required for this operation. For example, if three people are needed to operate a specific (labor) work center, type in '3'.

This field identifies the group of work centers to which this work center belongs. Work center groups are used to review workloads.

This field identifies the selected work center as being a 'labor' work center.

Use this field to assign a 'labor' work center to this operation. The work center site must match the site for the routing code, if defined.

Scheduling is not carried out for labor work centers as they are considered secondary and 'always available' (or available at the same time as the main work center). Their load is managed for information purposes only using the coefficients defined for the main work center.

 If the main work center is of type 'subcontracting' there is no associated secondary work center.

Use this field to define the number for this particular production resource that are required for this operation. For example, if three people are needed to operate a specific (labor) work center, type in '3'.

This coefficient helps with data entry. It is used to multiply the load times (setup time and run time) for a standard operation, if the 'recovery of the operation data' has been confirmed.

This coefficient is not recorded in the tables. It is set to 0 (zero) when loading a routing operation. If a standard operation specified for a routing operation is modified, it is set to 1. The coefficient can be entered on the operation detail line for a new routing operation, or in the Routing operation detail screen (available from the Actions icon) when set to 1.

Use this field to specify the actual time it takes to prepare this work center. This time forms part of the work center load. It is expressed in the time unit specified in the routing header or in the time defined for the standard operation, if a standard operation has been applied for this operation.

The operation time type conditions the production time entry.

The following values are possible:

• Proportional: the production time is proportional to the released quantity. It is expressed in hours and minutes (based on the time unit) for a given number of units (based on the management unit and basic quantity).
  With a proportional time type, the production time is entered in the operation time section and the rate section cannot be assigned.
• Rate: the production time is proportional to the released quantity. The rate is used to express the time in number of units per hour or minute, depending on the time unit.
  With a rate time type, the production time is entered in the rate section and the operating times, management unit and basic quantity cannot be entered.
• Fixed: the production time is independent of the released quantity. This time is expressed in hours or in minutes depending on the management unit.
  With a fixed time type, the production time is entered in the operating time section and the management unit, basic quantity and rate cannot be entered.

Depending on the resource being used, the number of decimals of the operation time can be insufficient to express the production time.

The management unit makes it possible to express the operation time for 1, 100, 1000 or a lot of units of parts to be produced.

If the management unit is chosen by lot, the size of the lot can be entered in the basic quantity.

The basis quantity entry depends on the management unit.

In effect, if the time is expressed for 1 unit, for 100 units or for 1,000 units, the basis quantity is forced, respectively to 1, 100 or 1,000 units.

However, if the time is expressed for a lot, the basis quantity can be entered. If the processed routing code is dedicated to a site, it is initialized by the lot size of the product-routing for this site.

The basis quantity entry format depends on the operation unit.

The operation time is the time necessary to manufacture the product described in the routing.

The operating time unit can be:

• expressed in hours or minutes (see the time unit),
• assigned to 1, 100, 1000 or a lot of units of the operation based on the management unit,
• proportional or fixed based on the type of operation time
  Example: Time unit = Hours Time type = proportional Management unit = Time for 100 Operation time = 2 Operation unit = Kg Finished product unit = A REL-OPE conversion coefficient = 0.5
  The operation time is equal to 2 hours for 100 Kg. If the Work Order is launched for 1000 units of finished product, the time necessary to produce this operation is 10 hours to obtain 500 Kg.

The rate is a number of units produced by minute or by hour according to the time unit specified in the routing header (for an operation), or in the standard operation itself.

The number of units is expressed according to the time unit.It can only be entered if the operation time type is the "rate".

Efficiency is a way to measure compliance to the preset standards. It can be calculated over a given period by work center: Standard hours calculated for a given production divided by the actual hours worked.

Efficiency makes it possible to correct the standard times of the routing (multiplying factor) according to the used resource.

Two efficiency rates are managed depending on the following:

• Work center: The rate is applied to all the routing operations that will take place at the work center.
• Routing operation: The rate only applies to the considered operation.

If both factors are entered, they add up.

The calculated operating time is corrected in the following way: work center efficiency * operation efficiency * time.

The WSTEFFINH - Work center efficiency history parameter (GPA chapter, MIS group) is used to specify whether the efficiency defined at work center level should be used on the routing operation.

• If WSTEFFINH is set to Yes, the efficiency entered in the work center is suggested by default when creating the routing operation with this work center. The calculated runtime = runtime entered * 1 / operation efficiency.
• If WSTEFFINH is set to No, the efficiency entered in the work center is combined with that entered in the routing operation. The calculated runtime = runtime entered * 1 / work center efficiency * 1 / operation efficiency.

This percentage is used to balance the quantities on the production operations based on the released quantity.

It is possible to introduce a shrinkage percentage on the work center, which is used to weight the planned runtimes for an operation using this work center by a loss or gain on the quantity produced for the work center.

This is the planned setting time to obtain the setting time allocated to the labor work center linked to the main work center.

This coefficient applied to the planned setting time to obtain the setting time allocated to the labor work center linked to the main work center.

This field is only available for entry if the labor work center is entered.

This is the coefficient applied to the planned operation time. It is used to obtain the operation time for the labor work center linked to the principal work center. This field is only available for entry if the labor work center is defined.

Operation times are subdivided as follows:

Proportional times are expressed for the production of an operation unit (and not in the stock unit of the finished product using the routing).

This coefficient helps with data entry. It is used to multiply the load times (preparation time, waiting time and post run time) for a standard operation, if the 'recovery of the operation data' has been confirmed.

This coefficient is not recorded in the tables. It is set to 0 (zero) when loading a routing operation. If a standard operation specified for a routing operation is modified, it is set to 1. The coefficient can be entered on the operation detail line for a new routing operation, or in the Routing operation detail screen (available from the Actions icon) when set to 1.

Preparation time is 'waiting time' set at the start of an operation.

 Preparation time is always expressed in hours. It does not use the time unit defined in the routing header (field Time unit). Preparation time is not applied to the work center load.

Although preparation time is waiting time it can be used for the time it takes to prepare for an operation on a work center. This might be time for settling liquids or cleaning a machine. For this type of scenario, that is when preparation time is used for setting time at the start of an operation, the resource must be available.

When scheduling preparation time the calendar for the defined resource is applied. This means that if, for example, a work center (machine or labor) runs from 08:00-12:00 and 13:00-17:00 with a break for one hour between 12:00-13:00, preparation time will be interrupted by the one hour break.

If the operation requires an 'emergency release', a reduction coefficient can be assigned that makes it possible to completely remove any preparation time.

Waiting time is 'delay time' that occurs after an operation. It is non-productive time such as drying time or cooling time that occurs after a process has been completed on a machine and until the machine can next be used.

 Waiting time is always expressed in hours. It does not use the time unit defined in the routing header (field Time unit). Waiting time is not applied to the work center load.

If machine time is required for an operation during the allowed waiting time you should add a new operation to this routing. A machine might be required for example, for drying or cooling components at a work center. The additional operation must be for the appropriate resource type, such as 'cooler'.

When scheduling time for these resources if, for example, a work center (machine or labor) runs from 08:00-12:00 and 13:00-17:00 with a break for one hour between 12:00-13:00:

• When scheduling waiting time the calendar for the defined resource is applied. Waiting time will be interrupted by the one hour break.
• When scheduling time for the additional resource the calendar for the defined resource is applied. Time will be interrupted by the one hour break.

Post operation, or post run time is a 'deadline' that occurs after waiting time. It is non-productive time, typically 'transfer time', or a transition period from one work center to the next work center that occurs after a process has been completed on a machine and until the machine can next be used.

 Waiting time is always expressed in hours. It does not use the time unit defined in the routing header (field Time unit). Waiting time is not applied to the work center load.

If operator time is required for an operation during the allowed post run time you should add a new operation to this routing. An operator might be required for example, for the transportation or carriage, or the transition between two work centers. The additional operation must be for the appropriate resource type, such as 'carrier'.

When scheduling time for these resources if, for example, a work center (machine or labor) runs from 08:00-12:00 and 13:00-17:00 with a break for one hour between 12:00-13:00:

• When scheduling post run time a neutral 24 hour calendar for the defined resource is applied. Post run time is not, therefore, interrupted by the one hour break.
• When scheduling time for the additional resource the calendar for the defined resource is applied. Time will be interrupted by the one hour break.

If the operation requires an 'emergency release', a reduction coefficient can be assigned that makes it possible to completely remove any post run time.

 When scheduling time for these resources, if both waiting time and post run (post operation) time has been declared for the operation only the largest of the two values is used.

Work order operation quantities are expressed in the operation unit. Use this operation unit to express operating time in a different unit to that of the product being produced by the routing.

For example, a product managed by unit is subject to three different operations, none of which produce intermediate stock:

• Mixing time (operation 1) is expressed for a lot with Kilogram as the unit;
• Extrusion time (operation 2) is a rate in meters per hour;
• Cutting time (operation 3) is expressed in hours per unit.

There is no need to create semi-finished products for each production phase.

The operation unit is associated with a conversion coefficient for the stock unit of the product being produced by the routing and the operation unit.

The Stock unit-Operation unit conversion coefficient is used to convert the released quantity of finished product into the quantity of the operation according to its unit.

It belongs to the coefficient table.

It is possible to enter a formula used to calculate the Stock unit-Operation unit conversion coefficient.

If this field is entered, it will have priority over the coefficient previously entered.

The technical sheet is used to record two types of information.

• the text describing the control process or the operating mode.
• a set of questions/answers in order to introduce a parameter entry during quality control or production tracking.
  The answers provided can be controlled via preset values and give rise to statistics.

Operation workbench
Information field that contains the name of the workbench to which the routing operation refers.

Operation image
Information field that contains the name of the image to which the routing operation refers.

The tool is represented by a product reference whose category is of tool type.

Field for information purposes.

Program number
Information field containing the name of the program that the operation routing refers to.

The subcontract type defines if an operation is carried out internally or if it is sent to an external (subcontract) supplier. Select one of the following values:

• No. The operation is never subcontracted. You cannot assign a subcontract product or a subcontract work center to this operation.
• Normal. The operation is always subcontracted. The factory does not have the required skills or toolings. The subcontract product is mandatory. The main (principal) subcontract work center is assigned as the subcontract work center.
• By exception. The operation is carried out internally. It can be subcontracted in exceptional circumstances such as when instances of overload or temporary issues occur. The subcontract product and the subcontract work center are mandatory.

Use this field to identify the service to be carried out by the subcontractor to execute the selected operations. The product category must be of type 'Service'.

This field identifies the group of work centers to which this subcontracted work center belongs. Work center groups are used to review workloads.

This field identifies the selected work center as being a 'subcontract' work center.

A subcontract work center can be used for the following: 

• Managing load issued to a subcontractor;
• Tracking subcontracted hours (if used for 'generic' subcontracted work);
• To represent a specific subcontractor.

A subcontract work center has the work center type set to 'Subcontracting'.

Routing operations are validated to ensure the work center site of a 'subcontract' work center matches the site for the routing code, if defined.

Enter the BP code or use the Lookup tool to search from the BP table.

This field indicates the code of the address to ship to.

You can view the detailed address information by clicking Address from the Actions icon.

• On creation, this field is no longer accessible when a delivery line is created.
• Once the delivery has been created, you can no longer modify this field but you can still display the detailed address information.
  You can modify the address after clicking Address/Delivery from the Actions panel.

Use this field to apply a generic price to a subcontract service. This price will be applied (by operation unit) throughout the order process.

Click Routing operation detail from the Actions icon to enter the details for this operation using the standard screen display mode.

Click Renumber from the Actions icon to renumber the routing operations.

Click Global renumbering from the Actions icon to renumber the routing operations.

 This action is only available if the Reference date (field DATREF) in the header information is blank.

Click Text from the Actions icon to view, enter or modify text associated with this operation. For example, information describing how to use the workstation, how to merge colors, how to use tools, the torsional movement to fix a screw.

Click Line revision from the Actions icon to change the details of an existing operation. When you select this action the selected operation is duplicated. The operation that displays the highest index number (field Index) is the new operation into which you can enter your amendments.

Click Line exclusion from the Actions icon to exclude an operation.

Click Line reintegration from the Actions icon to reintegrate an operation you have selected to amend (via the Line revision action) back into the routing. The new operation is deleted and the end date of the reintegrated operation removed.

 This action is only available whilst an operation is being amended (via the Line revision action). It is not available after you have selected to save the routing details (via the Save action in the Action panel).

This field displays the sequence number of this operation.

This field identifies the group of work centers to which this work center belongs. Work center groups are used to review workloads.

This field identifies the type of operation that is performed on the selected work center. This might be a machine, labor or a subcontracted operation. Work centers of type Subcontracting are managed externally by subcontract suppliers.

This field identifies the production resource that is to be used for this operation. This work center is the main (principal) work center for this operation. It can be a machine, labor or subcontract work center. The scheduling of the operations looks at the availability of this work center.

Work centers of type 'subcontracting' are managed using the lead time defined in the subcontract product record. Subcontract operation times are not used by the scheduling.

The description of the work center.

This field defines the type of production tracking that applies to this operation, as follows:

• No. This operation is not tracked manually.
• Normal tracking. This operation is tracked normally.
• Range. This operation and all the previous non-tracked operations are tracked automatically until the first operation is found that is set to Normal tracking or is itself included in a range of operations.

When the "production step" code is set to "yes" for an operation, the production reporting (receipt to stock of the finished product) can follow the end of the time entry.

For a given routing, the scheduling is only correct (and the routing validated) if there is a least one production step.

The next operation is used to link the routing operation in a logical order for the operational process.

This operation does not necessarily start at the end of the previous operation in the operational process as the scheduling describes the sequencing mode of the operations.

The next operation must be different from the processed operation, and must be part of the operations of the processed routing.

The last operation in the routing must have available a next operation set to zero.

Scheduling determines the way in which routing operations follow each other. It can take the following values:

• Absolute successor. Position is at the end of the longest operation in the routing.
• Overlapping wait = lots. The following operation can start after a period of time corresponding to the number of lots manufactured during the processed operation.
• Overlapping wait = time. The next operation can start after a period of time equal to a given overlapping time.
• Overlapping wait = quantity. The next operation can start when a given quantity over the processed operation has been produced.
• Start synchronization. The next operation is synchronized to start at the same time as the processed operation.
• End synchronization. The next operation is synchronized to end at the same time as the processed operation.
• All order operations parallel. The next operation is synchronized to start at the same time as the first operation.
• Subcontract synchronization. Code used automatically when a subcontracted operation is distributed over several supplier orders. In this situation the operation is split up and this code is used to link the various components to a single operation.
• Simple successor. Position is just after the previous operation.

Overlapping time is only accessible if the Scheduling field (SCDCOD) is set to Overlapping wait = time.

Overlapping time is always expressed in the routing Time unit (TIMUOMCOD field).

Overlapping quantity is only accessible if the Scheduling field (field SCDCOD) is set to 'Overlapping wait = quantity'.

An overlapping quantity is always expressed in the operation unit (field OPEUOM).

Work order operation quantities are expressed in the operation unit. Use this operation unit to express operating time in a different unit to that of the product being produced by the routing.

For example, a product managed by unit is subject to three different operations, none of which produce intermediate stock:

• Mixing time (operation 1) is expressed for a lot with Kilogram as the unit;
• Extrusion time (operation 2) is a rate in meters per hour;
• Cutting time (operation 3) is expressed in hours per unit.

There is no need to create semi-finished products for each production phase.

The operation unit is associated with a conversion coefficient for the stock unit of the product being produced by the routing and the operation unit.

The number of overlapping lots is only accessible if the automatic scheduling is set to "overlapping with waiting time = number of lots".

Click Schedule detail from the Actions icon to enter the scheduling details for this operation using the standard screen display mode.

Click the Header texts action to view, enter or modify text associated with this routing.

Click the List of WOs action to view the list of work orders using this routing.

Click the Codes action to allocate the routing codes that are to be used for this routing whilst it is being prepared and when it is complete.

Click the Revision action to create a revised version of this routing. You can choose to increment the major or the minor version. The new routing will be created with the status 'In development' as this will enable you to change the routing details as required. For example, to correct an operation you might create a new minor version; to add another operation you might create a new major version.

 You cannot change any key elements of a routing once it has been validated and activated. If an operation is incorrect or you need to add another operation, for example, create a revised version of the routing, correct the operations and revalidate.

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Click the Validation action to validate this routing. This will check the coherence of the routing operations is correct and enable you to return to the definition to correct it if necessary. For example, it checks the last operation does not have a next operation, the schedule does not loop and at least one production operation has been declared. Once validation is complete the Compliant flag is checked (set to 'Yes'), this routing is activated and its status is changed to 'Available to use'. The System Log is updated accordingly.

Click the Management action to view and manage all versions of this routing at this site. You can use this action to do the following:

• Set the final date of the validity period for the current version of this routing
• Add an exception date to a specific version (major or minor) of this routing, should the version need to be used outside its validity period.

Multiple major versions indicate that there has been a significant change to the original routing, that is, the 'form, fit or function' changed. Where a minor version is displayed compatibility with the major version has been maintained, there has simply been a minor change to the associated major version.

 To add new versions (major or minor) of this routing please use the Revision action.

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