Tuesday, 27 August 2013

Production Control Training 2 - BOM, Routes, & Operations - Discrete Manufacturing AX 2012 R2

In the last part we have set up everything from production units to calendars, and resources. So now lets move on to creating our BOM, Routes and Operations. Before we start let me give you a brief on the items I have created for the BOM.


Step 1 - Create the Products


Product ID
Name
Product Dimensions
Storage Dimensions
Tracking Dimensions
Unit
TANJ0001
Tanjore Painting
Size and Style
Site/Warehouse
None
ea

In the last part we have set up everything from production units to calendars, and resources. So now lets move on to creating our BOM, Routes and Operations.

Before we start let me give you a brief on the items I have created for the BOM.

Manufactured Item


Product ID
Name
Product Dimensions
Storage Dimensions
Tracking Dimensions
Unit
TANJ0001
Tanjore Painting
Size and Style
Site/Warehouse
None
ea

Create different sizes and styles I created three sizes and 3 styles

Ingredients

Product ID
Name
Product Dimensions
Storage Dimensions
Tracking Dimensions
Unit
TANJ0002
Glass
Size
Site/Warehouse
None
ea
TANJ0003
Frame
Size
Site/Warehouse
None
ea
TANJ0004
Decorations
None
Site/Warehouse
None
Pack
TANJ0005
Paint
Color
Site/Warehouse
Batch
ml

The glass and frame will have the same 3 sizes and variants. For the paint create as many variants of colors as you want. I created 5.

Next Release the products and continue with the basic item setup such as

·      Item Group
·      Item Model Group
·      Dimensions
·      BOM Unit
·      Purchase Unit
·      Sales Unit
·      Inventory Unit

For the sake of simplicity we are going to keep all four types of unit the same as in the tables above.

We will also have to set up the cost group for each item. Do not enter any values in the prices group because this will get updated when we create the item prices from the costing version. I have gone over cost groups in my last post.





Step 3 - Set up Item Cost Prices

Lets set up the item cost prices for all of "ingredients" we created.

First lets add the overhead for our items.

(If you are new to AX skip the following brief on Costing Sheet Setup)

Costing Sheet

This is only for "purchase prices", in this post we will be setting up the "cost price" so if u skip the costing sheet setup that is fine. I will be going much further in depth on the topic of costing so do not get nervous if you do not understand it fully yet.

Indirect Cost can only be set up for the price type "purchase price" and cannot be set up of price type of "cost" in this training we are using the price type of "cost". So this is just a step I want to introduce but will not be applicable for this lesson.


So go to the costing sheet form. Inventory Warehouse Management > Setup > Costing > Costing Sheet


Now if you see there is Overhead tab under "Cost of Purchase". Click on that then from the grid on the side go to the calculation tab.

On the bottom half of the form create a new line and select the costing version and then site. I chose site 5 because all of the items in my BOM are tagged with site 5. And i have gone ahead  and select "ALL" in the Valid For field because i want it applicable for all the items. Then set the percentage. Save the record and Activate it.

Cost Price

Now for setting the actual price for the item.

Go to the Costing Versions form.

Inventory and Warehouse Management > Setup > Costing > Costing Versions



From the action pane click on prices and then item price. Create a new line for our item and set the price.


I have set this up again with site 5. This is our paint so in the Price Quantity field I set a value for 5. because i want the price to be applicable for 5ml of paint.

In this post we are only going over "COST" price type.

There are three price type in AX 2012
  • Cost
  • Purchase Price
  • Sales Price
Do this for all the items and then activate the prices.

Step 4 - Create the BOM

Go to the Released Products List Page and select TANJ0001.

From the action pane go to the Engineer Tab and click on Lines.

Go ahead and add all of "Ingredients" to the BOM Lines.


Now i only have only created one BOM Version for one of the sizes, but you free to experiment and create more than one BOM Version.

Now that this done let us move on to creating a Route.

Step 5 - Create the Route Version

Go to the Route List Page.

Production Control > Common > Routes > All Routes.

Go ahead a create a new Route.

When you click New the Route Version forms comes up. Route Versions are similar to BOM Versions where we can create different routes according, to a date range, quantity, site, and product variants.

Again in this case we re only going to create one Route Version.


Step 6 - Create Operation Relations

In the last post the following operations were created.

  1. Sketching
  2. Outlining
  3. Painting
  4. Decorations
If you are catching up quickly create them so we can start with attaching relations to out operations.

Go to Production Control > Setup > Routes >Operations

First select the Sketching operations and from the action pane click on relations.

We have to set up the relations on all four of the operations before we can proceed to adding the operations in the route.

On the overview tab select New.

We have to first create a relation to the Item. Select the "Table" option in the item code field and then select the item. In our case we will be creating a relation to our manufactured item which is "TANJ0001".

Second let us create a relation with the route we created earlier. Under Route Code select the "Route" option and then select the appropriate route as the route relation. 



In the General Tab

Specify the Site and Route Group. Route Group specify what costs are used during a production. For example we can specify if the setup, run time, or quantity costs should be calculated for any production run.

The property field is connected to the resource through the calendar we have assigned to the resource is used for scheduling similar operations together. We will talk about scheduling and the property field later on.




Skip the setup tab and lets move on the "Times" tab. Again we will be going over the exact meaning of each of these times coming up after we finish the tutorial.

Operation Setup 



The "formula" field  specifies how Run time for the operation should be calculated. You can select the following options: 
  • Standard: the manually entered values for Run time are used. 
For capacity there is no need to manually enter a run time in the times tab of the operations relations form.

For Example if we choose the capacity the as the formula and the capacity for my operation is 2 units per hour and production is for 10 units. The Calculated run time would be 5 hours. The added advantage with capacity is that in certain situations it is required that the capacity be calculated with a factor.
  • Capacity: the process time is calculated on the basis of Capacity that is specified in Resources form, the factor.
The other two formulas batch and resource batch are for process manufacturing so we will not be looking at those options today.

Operation Times


Please read up on the different times from MSDN.

I want to mention that "Hour/Time" is used to convert hours in to decimals.

Finally in the "Resource Requirements", click new in the grid action pane and select the resource you created for the sketching operation.
























Do this for all of the 4 operations.

Now we will make the add the operations to out Route we made earlier.

Go back to

Production Control > Common > Routes > All Routes

Select the Route we made earlier and double click on it or click on Edit from the Action Pane.

You will get a blank form with two grids.

In the top grid create a new record and start adding your operations in order. Refer to the example on the bottom.


After adding these routes we have to go ahead and update the route. So from the action pane click on functions and select route updating.



By updating the route we can go ahead and link the operations to specific bom lines from the bom lines designer or BOM lines form.



That is about it for this training. We have gone over a lot. Please practice this and if you have any questions do not hesitate to ask.

Some of the next few posts will be a little more in depth on the costing side of production once a run is completed.









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