Routing management

The routing code describes the process involved in manufacturing (producing) or processing a product. It provides 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, which is defined as a bill of material, or a generic reference to a parent routing, which is linked to several products.

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 edited.

If the routing is version managed, the version of the routing that applies on the defined date.

If the routing is not version managed, the routing operations with a validity period that span the defined date.

If blank and the routing is version managed, you can enter the version details to display the applicable date.

Indicates if this is a major version of the routing. Major versions might be used where there have been increased or significant changes in functionality. The "form, fit, or function" has changed.

If you’re creating a new routing and routing versions are managed for the product code, enter 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 needs to match the format for the sequence number counter defined on the product record.

If you’re viewing an existing routing, this field displays the major version of the 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.

Indicates if this is a minor version of the routing. Minor versions might be used where there have been minor features or changes in functionality, or significant fixes applied to a specific major version.

If you’re creating a new routing and routing versions are managed for the product code, enter 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 needs to match the format for the sequence number counter defined on the product record.

If you're viewing an existing routing, this field displays, in conjunction with the major version, the minor version of the 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 the product, or the specific version or revision of the 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 creating or editing the routing for the product until the change request identified is closed. At that point a change to the 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 editing the routing should you decide to do so.

The status on the shop floor of the preparation of the operations and tools in the routing.

In development: The routing is not yet complete.

Available to use: The routing is complete and the coherence of the routing operations was validated.

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

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

You cannot edit this field after the version is validated if the routing code defined in the Routing field is version managed.

Defines how time for the operations in the routing is expressed. The time unit can be hours or minutes.

The time applies 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 was declared.

If the scheduling is correct, the Compliant checkbox is selected.

If the scheduling is not compliant, you need to check the following:

• The scheduling details
• An operation was added
• If the replacement date of an operation was modified
• If the replacement date of an operation has affected the sequence of operations
• An operation was deleted

Controls amendments to work orders that have the routing assigned. This includes work order amendments such as replacing work centers, replacing components if there are shortages, or changing machinery setup times.

No change: The components and the operation details cannot be edited.

Materials change: Only the components can be edited.

Operations change: Only the operations can be edited.

Change materials and operations: Both the components and the operations can be edited.

The operation validity period start date.

If the routing is version managed and you're editing an existing operation (the Index field is populated), the default start date is tomorrow.

The operation validity period end date.

If the routing is version managed and you're editing an existing operation, the previous operation (the Index field is blank or lower than the operation) defaults to the current date.

The standard operation to use to simplify creating an 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 standard operation will provide default values for many of the fields in the operation.

Identifies the type of operation that's performed on the work center. This might be a machine, a labor, or a subcontracted operation.

Subcontracting type work centers are managed externally by subcontract suppliers.

Identifies the production resource to use for the operation. This work center is the main or principal work center for the operation.

The resource can be a machine, a labor, or a subcontract work center. Operation scheduling considers the availability of the 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 Subcontracting type work center, the Subcontract code (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 enter a temporary subcontracting code for the subcontract work center. Scheduling is carried out by priority on the main (workshop) work center when creating a work order. You can replace the work center with the subcontract work center if the operation is subsequently subcontracted.

The labor work center assigned to the operation. The work center site needs to match the site for the routing code, if defined.

Scheduling is not carried out for labor work centers. They’re 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.

This coefficient helps with data entry. It’s used to multiply the load times (setup time and run time) for a standard operation, if "recovery of the operation data" was confirmed.

This coefficient is not recorded in the tables. It’s set to 0 when loading a routing operation. If a standard operation specified for a routing operation is modified, it's 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.

Specifies the actual time that it takes to prepare the work center.

This time forms part of the work center load. It’s expressed in the time unit specified in the routing header or in the time defined for the standard operation, if a standard operation was applied for the operation.

The operation time type applied to the production time entry.

• Proportional: The production time is proportional to the released quantity. It’s expressed in hours and minutes, as based on the time unit for a given number of units, which is based on the management unit and basic quantity.
  With a proportional time type, the production time is entered in the operation time section. 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. 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. The management unit, basic quantity, and rate cannot be entered.

Depending on the resource being used, the number of decimals for 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, 1,000, or a lot of units of parts to be produced.

If the management unit is by lot, the lot size can be entered as the base quantity.

The base quantity depends on the management unit.

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

However, if the time is expressed for a lot, the base quantity can be entered. If the processed routing code is assigned to a site, it's initialized for the lot size of the product-routing for the site.

The base quantity entry format depends on the operation unit.

The time needed to manufacture the product described in the routing.

The operating time:

• Is defined in hours or minutes (Time unit field)
• Is expressed for 1, 100, 1,000, or a lot of units of the operation based on the management unit

• Can be proportional or fixed based on the operating time type

  Example

  Time unit = Hours
  Time type = proportional
  Management unit = Time for 100
  Operating time = 2
  Operating unit = kg
  Finished product unit = un
  REL-OPE conversion coefficient = 0.5
  The operation time is equal to 2 hours for 100 kg. If a work order is created for 1,000 units of the finished product, the time needed for the 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 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.

2 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 the work center. The calculated run time = run time 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 run time = run time 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’s possible to introduce a shrinkage percentage on the work center, which is used to weight the planned run times for an operation using the work center by a loss or gain on the quantity produced for the work center.

The coefficient applied to the planned operation time 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. They're not in the stock unit of the finished product using the routing.

This coefficient helps with data entry. It’s used to multiply the load times (setup time and run time) for a standard operation, if "recovery of the operation data" was confirmed.

This coefficient is not recorded in the tables. It’s set to 0 when loading a routing operation. If a standard operation specified for a routing operation is modified, it's 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 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. When preparation time is used for setting time at the start of an operation, the resource needs to be available.

When scheduling preparation time, the calendar for the defined resource is applied. This means that if, for example, a machine or labor work center runs from 08:00 to 12:00 and from 13:00 to 17:00 with a 1 hour break from 12:00 to 13:00, preparation time will be interrupted by the 1 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’s non-productive time.

Waiting time is not applied to the work center load. It's for periods such as drying time or cooling time that occurs after a process was completed on a machine and until the machine can next be used.

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

When scheduling time for these resources if, for example, a machine or labor work center runs from 08:00 to 12:00 and from 13:00 to 17:00 with a 1 hour break from 12:00 to 13:00:

• When scheduling waiting time: If the resource needs to be available, the calendar for the resource also applies to the waiting time. For this example, time will be interrupted by the 1 hour break.
• When scheduling time for the additional resource: The calendar for the defined resource also applies to the waiting time. The additional resource time will be interrupted by the 1 hour break.

Post operation, or post run time is a "deadline" that occurs after waiting time. It's non-productive time.

Post run time is not applied to the work center load. It's typically "transfer time", or a transition period from one work center to the next work center that occurs after a process was completed on a machine and until the machine can next be used.

If operator time is needed for an operation during the post run time, you should add a new operation to the routing. An operator might be needed, for example, for the transportation or carriage, or the transition between 2 work centers. The additional operation needs to be for the appropriate resource type, such as "carrier".

When scheduling time for these resources if, for example, a machine or labor work center runs from 08:00 to 12:00 and from 13:00 to 17:00 with a 1 hour break from 12:00 to 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 1 hour break.
• When scheduling time for the additional resource, the calendar for the defined resource is applied. Time will be interrupted by the 1 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.

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

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

It belongs to the coefficient table.

The formula used to calculate the stock unit-operation unit conversion coefficient.

The technical sheet. It records 2 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 using preset values and to provide statistics.

Defines if an operation is carried out internally or if it's sent to an external subcontract supplier.

• No: The operation is never subcontracted. You cannot assign a subcontract product or a subcontract work center to the 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.

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 that the work center site of a subcontract work center matches the site for the routing code, if defined.

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

Select Line revision from the Actions icon to change the details of an existing operation.

When you select this action, the selected operation duplicates. The operation that displays the highest index number in the Index field (RPLIND) is the new operation that you can edit.

Select Line reintegration from the Actions icon to reintegrate an operation you’ve selected to edit using the Line revision action, back into the routing. The new operation is deleted and the end date of the reintegrated operation is removed.

Identifies the type of operation that's performed on the work center. This might be a machine, a labor, or a subcontracted operation.

Subcontracting type work centers are managed externally by subcontract suppliers.

Identifies the production resource to use for the operation. This work center is the main or principal work center for the operation.

The resource can be a machine, a labor, or a subcontract work center. Operation scheduling considers the availability of the work center.

Subcontracting type work centers are managed using the lead time defined in the subcontract product record. Subcontract operation times are not used by the scheduling.

Defines the type of production tracking that applies to the operation, as follows:

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

When selected 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's a least 1 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 needs to be different from the processed operation, and needs to be part of the operations of the processed routing.

The last operation in the routing needs to 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 was 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 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 (SCDCOD) is set to Overlapping wait = quantity.

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

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

Select the Codes action to allocate the routing codes that are to be used for the routing while it's being prepared and when it's complete.

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

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New version

Select the Validation action to validate the routing. This checks that the coherence of the routing operations is correct and enables 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 1 production operation was declared. After validation is complete, the Compliant checkbox is selected, the routing is activated and its status is changed to Available to use. The system log is updated accordingly.

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

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

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

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