Configuration of Production with Backflushing: Implementation Activity

In this implementation activity, you will learn how to implement production processes with the backflushing of materials and labor.

Story

Suppose that the production department of SweetLife Fruits & Jams started to pack the assembled juicers before shipping them to customers. So the production process will include the assembly operation and the packing operation. Each operation is performed in a specific work center. In the work center where packing is performed, workers put each assembled juicer in a box, fill in the box with packing peanuts, and seal the box with packing tape. For packing a juicer, the following materials are required: one packing box, approximately 3 meters of packing tape, and approximately 2 liters of packing peanuts. The exact quantity of the peanuts and the tape is not known until the workers finish packing, so these materials should be backflushed, as should the box so that production managers do not release any materials for the packing operation manually. Also, the workers of this work center pack not only juicers but other items, so the time they spend on packing juicers should also be backflushed.

Acting as an implementation manager, you need to implement the production of juicers with material and labor backflushing in the system—that is, create a work center dedicated to the packing operation and a bill of material to be used for the assembly and packing of the juicers.

Configuration Overview

In the U100 dataset, the following tasks have been performed for the purposes of this activity:

  • On the Warehouses (IN204000) form, the WORKHOUSE warehouse has been defined, and its locations include MGI and MTL.
  • On the Stock Items (IN202500) form, the CFJFRUIT, PULPCONT1L, JUICECUP05L, MRBASE, FNSIEVE, GRDISC01, PACKTAPE, PPEANUTS, and PACKBOX stock items have been defined.
  • On the Work Calendar (CS209000) form, the MAIN work calendar has been defined, which is used for standard working hours.

Process Overview

In this activity, you will do the following:

  1. On the Work Centers (AM207000) form, create a work center for packing.
  2. On the Bill of Material (AM208000) form, create a bill of material for the assembly and packing of the juicers.

System Preparation

Before you start performing the activity, do the following:

  1. As prerequisites to the current activity, complete the following activities in the specified order:
    1. System Preparation for Manufacturing Implementation: Implementation Activity so that the needed settings have been specified in a company with the U100 dataset preloaded
    2. Configuring Work Centers: Implementation Activity so that the work center for the assembly operation has been created in the same company with the U100 dataset preloaded
  2. Sign in to this company (in which the prerequisite activities have been performed) as a system administrator with the gibbs username and 123 password.

Step 1: Creating a Work Center

To create a work center where the packing operation will be performed, do the following:

  1. On the Work Centers (AM207000) form, add a new record.
    Tip: To open the form for creating a new record, type the form ID in the Search box, and on the Search form, point at the form title and click New right of the title.
  2. In the Summary area, specify the following settings:
    • Work Center: WCR200
    • Description: Work center for packing
    • Warehouse: WORKHOUSE
    • Active: Selected
  3. On the General tab, specify the following settings:
    • Standard Cost: 12
    • Basis for Capacity: Crew Size
    • Scrap Action Default: No Action
    • Backflush Materials: Selected
    • Backflush Labor: Selected
    • Allow Clock Entry for Multiple Production Orders: Cleared
    • Control Point: Cleared
    • Outside Process: Cleared
  4. On the Shifts tab, do the following:
    1. Notice that the row for the 0001 shift has been added. (The row for the first shift is always added automatically because a work center must have at least one shift.)
    2. In this row, specify the following settings:
  5. On the form toolbar, click Save.

Step 2: Creating a Bill of Material

To create a bill of material that includes the packing operation, do the following:

  1. On the Bill of Material (AM208000) form, add a new record.
  2. In the Summary area, specify the following settings:
    • Revision: A
    • Hold: Selected
    • Inventory ID: CFJFRUITBF
    • Warehouse: WORKHOUSE
    • Start Date: 1/1/2023
    • End Date: Empty
    • Description: A bill of material for the assembly and packing of juicers
  3. On the form toolbar, click Save.
  4. Add an assembly operation as follows:
    1. On the toolbar of the Operations table, click Add Row.
    2. In the row, specify the following settings:
      • Operation ID: 010
      • Work Center: WCR10

        You created this work center for the assembly of juicers in Configuring Work Centers: Implementation Activity (which was a prerequisite to the current activity).

      • Setup Time: 00:30
      • Run Units: 3
      • Run Time: 01:00
      • Backflush Labor: Cleared
    3. On the Materials tab, add rows for the items listed in the following table, specifying the listed settings for each.
      Inventory ID Qty. Required
      PULPCONT1L 1
      JUICECUP05L 1
      MRBASE 1
      FNSIEVE 1
      GRDISC01 1
    4. On the Tools tab, add rows for the tools listed in the following table, specifying the listed settings for each.

      You created these tools in Configuring Production Cost Drivers: Implementation Activity.

      Tool ID Qty. Required Unit Cost
      HAMMER 1 0.02
      SCREWDRIVER 1 0.20
  5. Add the packing operation as follows:
    1. On the toolbar of the Operations table, click Add Row.
    2. In the row, specify the following settings:
      • Operation ID: 020
      • Work Center: WCR200
      • Setup Time: 00:00
      • Run Units: 3
      • Run Time: 01:00
      • Backflush Labor: Selected
    3. On the Materials tab, add rows for the items listed in the following table, specifying the listed settings for each.
      Inventory ID Qty. Required UOM Backflush Materials
      PACKTAPE 3 METER Selected
      PPEANUTS 2 LITER Selected
      PACKBOX 1 EA Selected
  6. On the form toolbar, click Save.
  7. In the Summary area, clear the Hold check box. The status changes to Active.
  8. On the form toolbar, click Save.

You have successfully created the bill of material that production managers will use to create production orders for juicers to be assembled and packed.