Saturday, 24 August 2013

Production Control Training 1 - Calendars, and Resources - Discrete Manufacturing AX 2012 R2

Lets get back to some production in AX 2012.

If you have not done so please read my previous posts:
  1. Discrete Manufacturing AX 2012 R2 Bill Of Materials - Part 1 - The Fundamentals 
  2. Discrete Manufacturing AX 2012 R2 Bill Of Materials - Part 2 - The Fundamentals  
In this tutorial I want to discuss routes and operations.

Scenario - Tanjore Paintings Manufacturing Ltd. wants to implement AX 2012. TPM Ltd. operations are from 9am - 5pm 7 days a week. We will also have to set up the calendars for the same.

Tanjore Paintings have 4 Operations and costs will have to be reported separately for each operation.

1. Sketching
2. Outlining
3. Painting
4. Decoration 


Since we are setting up a new production unit for Tanjore Paintings. 
  1. Create a new Site
  2. Inbound Warehouse 
  3. Outbound Warehouse
  4. Production Unit (Fig 1)
  5. Cost Groups (Fig 2)
  6. Shared Categories (Fig 3)
  7. Cost Categories (Fig 4)

Create a Production unit and define the input and output warehouse.

Fig 1

Create 4 cost groups as per the requirement above.

The Two fields in the general tab do not affect any process in production they are only for reporting purposes.

  • Set the type as Direct Manufacturing
  • Set the behavior as Fixed Cost
  • Set the profit setting to standard but do not assign a value, we will revisit this at a later point.
Click on posting and set up the price variance accounts.

Fig 2

Before we can create any cost category we have to create Shared Categories so create 4 for all the 4 operations and select eh check mark for "Can be used in Production"  for all 4 of them.

Fig 3
Create the all 4 cost Categories and set the ledger accounts as well as the appropriate cost group.

Then click on the prices button to set the price. (Fig 5)
Fig 4

If you are working with the Demo Data for AX 2012 then you will already have a Costing Version. If not create a costing version.

Select the same site as per the production unit you set up earlier. After this is saved click activate.

Fig 5
I have created 4 new Operations in sequence. Before we can set up the relations and routes we will set up calendars, resources, resource groups, cost groups, and cost categories.
Fig 6
Step 1.  Resource Calendars and Working Time Templates

Organization Administration > Common > Calendars > Working Time Templates

Create a new template and name it Tanjore.

Then click on the Monday Tab and add a new timing. Since there are no shifts we will simply add one entry that 9:00 AM - 6:00 PM with a 100% efficiency.

 Then we will copy this to the all the  other days. So in the action pane click on the "Copy Day" and do it for all the 7 days.

Next set up the calendar tanjore.

Organization Administration > Common > Calendars > Calendars

Create a new calendars and name it Tanjore.

Efficiency:  The Efficency if field is used to calculate the capacity available for the resource. The formula used for calculating the Scheduling time is the Time multiplied the efficiency. 

Scheduling time = Time * 100/Efficiency percentage. 9 hours are available and the efficiency is 75 % then the available time is 6.75 hours. If there are multiple shits then with different efficiencies this would be the form to enter that information.

Click on the Working Times in the Action Pane. 

Then Click on Compose Working Times.

The following form will open. We are going to create the working times for 1 year and select the Working Time Template we created earlier.

Click Ok and the previous form which was empty will now be populated.

Setting up calendars is a prerequisite creating resources because every resource has to have a calendar attached. 

Step 2. Set up Resource Groups

Organization Administration > Common > Resources > Resources Groups

Create a new group.

I have named it Tanjore Paintings and assigned site 5.

Assign the Production Unit you created in the Prerequisite part of this tutorial

Leave  WorkCell  as it is used for Lean Manufacturing.

For this scenario we are going to leave the default value Operations Scheduling percentage of 100%.

Change this value if you want to control percentage of daily capacity that is handled for each production that is run.

Finite Capacity  specifies if the resource has a limited or unlimited capacity.

Let us skip over the operations and ledger fast tabs because we will be setting these values on the resource. Go directly to the financial dimensions fast tab to set the financial dimensions that will be used as the default financial dimensions.

Then add the calendar you created within the calendar fast tab.

Step 3. Set up Resources

Organization Administration > Common > Resources > Resources

Create a new resource. This is simple production so there will not be any simultaneous operations. We will be creating a resource for each operation.

Set human resource as the type of resource and then select the worker.

Then again we have to set the scheduling parameters, such as efficiency and operation scheduling percentage, finite capacity.

The exclusive check box will make this resource unavailable until the production has finished.

If we do not set efficiency over here it will be used as the value on the calendar. For operation scheduling percentage and finite capacity will be used from the resource group if we do not specify any value on the resource form.

We will leaving not focus on the time fields as these will be more relevant when we are setting up the operation relations.

Add the cost categories you made earlier to the resource form.

The financial dimensions will be taken from the resource group.

Set up the ledger accounts for the resource and in the resource groups tab select the resource group and the associated calendar.

Remember to create a 4 resources.

  1. 5111  - Sketching    - Human Resoruce
  2. 5112  - Outlining     - Machine
  3. 5113  - Painting       - Human Resource
  4. 5114  - Decorations - Human Resource

We will be creating operation relations and routes in part 2 of this training.

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