Sage x3 Fundamentals Manufacturing

May
2011
V6.1
Training Course
OP203: Fundamentals Manufacturing
/ © Sage 2010
Timing and Breaks
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emails during these breaks.
If you wish to meet someone, you can inform him or her about
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2 / © Sage 2010 OP203: Fundamentals Manufacturing

Presentation
Who are you?
What are your expectations

of this course?

Sage ERP X3 Fundamentals Sage ERP X3 Advanced Sage ERP X3 Expert
Distribution
Contracts (Purchasing and Sales) Distribution and
CB 101 – 102 Loan Orders Inventory
Introduction & Packaging & Shipment Preparation Purchasing Subcontracts
Purchasing Signature Management Pre-Allocations (Pegging Function)
Functional Overview
Sales and Purchasing Prepayments
(3 days) TEC102 Radio Terminals
Sales Reps and Commissions
Development Sourcing: RFQs, Responses
Carrier Management
(4 days) Inter-Site and Intercompany Transactions Manufacturing (5 days)
Invoice Elements (Purchasing & Sales) Configurator
Kits, Options & Variants
Weighing
Price List Management (Advanced)
TEC103 Manufacturing (4 days) Optimisation ILOG
Installation Advanced Global Manufacturing

Production Costing and WIP Posting Finance
(4 days)
Finance Multi-Legislation Set Up
Bank Communication & Reconciliation Operating Budgets
FIN201 - Budget Control/ Analytical Budget
Stock Interface
Finance Financial Data Extraction
(4 days) Statements & Reminders Pre-Consolidation
Automatic Journals & Dimension Defaults Analytical Allocations
Advanced Payment Transactions
Factoring
Month and Year End Processes
OPE201 - TEC101 - Fixed Assets
Tools & Development
Distribution Common Tools Inventory (3 days)
Connectors
(3 days) (3 days) Allocation Rules (Advanced)
Java Bridge Serveur
Stock Counts
Components
Serial Number Management
Eclipse
Reodering Replenishment Storage Plan
LDAP integration
Valuation Methods and Price Adjustments
Interface Import/Export
and cost calculations
OPE202 - OPE203 - Quality Control & Sampling
Netvibes
Inventory Manufacturing Sage Search
Tools & Development
(2 days) (3 days)
You Advanced Common Tools
Are Advanced Development
Here
Course Map
4 Title of the Presentation
Objectives
To be able to create a manufacturing data set.
To be able to manage the priority and capacity planning through

Sage ERP X3.
To understand all the possibilities in the manufacturing flow :
WO creation and modification
Tracking
Closing
Costing

Pre-requisites
Sage ERP X3 Introduction (CB101)

Sage ERP X3 Functional Overview (CB102)
Sage ERP X3 Inventory (OPE202)
Knowledge on Manufacturing management

Course Contents
Preamble
Work Orders
Common data
Work Order Management
Capacity and Load
Modifying Work Orders
Tracking
Work Orders close and cost
Appendix
Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
4. WORK ORDER MANAGEMENT
5. CAPACITY AND LOAD
6. MODIFYING WORK ORDERS
7. TRACKING
8. WORK ORDERS CLOSE AND COST
9. APPENDIX

1. Preamble
Chapter Objectives and Contents
Chapter Objectives Chapter Contents
Understanding the CIM (Computer Integrated

The definition
Manufacturing) context
Understanding the priorities analysis The planning sequence
Introduction to Volume-Variety illustration

Understanding the Planning Methods
Available tools

Understanding the CIM context
Definition
 Focuses on managing a certain volume of data
 Manages priority planning and capacity planning
 Answers questions: what do I need to produce, when, how many and how
 It tends to reduce stock, shortages, delays…
 It gives real time reports
 Data must be accurate
 Continuous improvement efforts are recommended (to shorten lead times,
avoid waste…)
 Updating of data must be rigorous

Understanding the priorities analysis
The planning sequence
PLANNING MATERIAL DRIVEN CAPACITY DRIVEN

SEQUENCE
1 PRODUCT PRODUCT
1 • S&OP*, Forecast, MPS*…
2 PRIORITY PLANNING CAPACITY PLANNING

2 • MRP*… • Finite capacity
3 CAPACITY PLANNING MATERIAL PLANNING

3 • Finite capacity • MRP
* S&OP : Sales & Operations Planning

* MPS : Mastered Production Scheduling
* MRP : Material Requirement Planning

Understanding the Planning Methods
Demand lead time constraints and cumulative lead time
ETO MTO ATO FTO MTS

.
Customer
Lead Time
ETO : Engineer To Order

Competition responses?
MTO : Make To Order
ATO : Assemble To Order
FTO : Finished To Order
MTS : Make To Stock

Understanding the Planning Methods and Tools
Introduction to Volume-Variety illustration: the 4 zones
Variety
1
ETO
Project
2
Job shop MTO
Intermittent
ATO 3
Batch
Repetitive FTO
4
Line
Continuous MTS
Volume
Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

2. Work Orders

Understanding work order place inside The module logic
the X3 ERP CIM module Definition of a Work Order
Clarify the necessity of the manufacturing
The Demand/Supply balance logic
releases in the industrial firm
Life of a work order
Understanding the different status of a Time fences and possible actions
work order Short term and medium term horizon
logics
Understanding the decision tools to make Load/Capacity balance logic to
the work done by the industrial firm complement the Demand/Supply balance
operators logic
Understanding the work order printing Learn about the Work Order shop packet
logic content

Understanding work order place inside the CIM module
The module logic
Work orders
Dispatch
management
Manufacturing
planning Production
tracking
Demand analysis Feedback
CIM
Data base
Improvement
management
Manufacturing
Common Demand Tracking Feedback
data • MPS-MRP
• X3 • Workbenches • Material • Costing
• Product Forecasts tracking • Reports
categories • Analysis
entries
(Materials & • Operation • Comparisons
• Products • X3 Sales tracking
Loads)
• Product site order • Production
• Purchases
• Bill of • Releases
tracking
Material
• Modifications
• Routing
• Prints

Exercise 2.1 – Preparation

Work order definition
Routing
BOM*
Product
* BOM : Bill Of Material Work Order

Complete manufacturing flow
Single Single WO Single WO Single WO Single WO Single WO Single WO Single WO

WO or or Mass or Mass or Mass or Mass or Mass or Mass or Mass
Mass scheduling
allocation
WO WO Stock Load WO shop Time Material Completed Qty Closure/ Costing

Planned Firm allocation scheduling packet tracking tracking tracking Completion
Automatic Automatic Automatic Automatic Automatic Automatic

Common flow
Work Orders Stock Change Production Tracking Work Order Close WIP
(GESMFG) (GESSCS) (GESMTK) (FUNMCLOSE) Finalization
(FUNWIPMFC)
Time
Tracking
(FUNBENCHO)
Work Manufacturing Plan Mass closure/ WIP

Orders (FUNBENCHI) completions Finalization
(GESMFG) (FUNTDUCLO) (FUNWIPMFC)
Material Tracking Plan

(FUNBENCHM)
and Work Orders Production tracking Work Order Close WIP

(GESMFG) (GESMFG) (FUNMCLOSE) Finalization
(FUNWIPMFC)
BOM Routing
Product

Priority planning
The Demand/Supply balance logic
S&OP : The forecast values and requirements from the sales

S&OP information system and costing/profitability analysis are inputs
Category to the Sales and Operations Planning phase.
MPS : Master Schedule items are planned (those items that

Product
MPS greatly influence profits or consume critical resources).
Planning the master schedule items separately leads to a
reduction in stock levels and improved delivery performance.
Product site MRP MRP : Materials requirements planning is the final step in the
planning process. The output of MRP is either a planned work
order, a purchase requisition, or a planned purchase order.
Bill of Material
PAC PAC : Production and Activity Control (Tracking)
Demand
Supply

Understanding the main status of a work order
Order status
Release
Plan Release Close

Suggested Planned Firm Physical Process Closed
Life of a Work Order

WO shop
packet Tracking Complete Costing
Printed In Completed Closed &
Pending
progress Costed

Understanding time fences and WO status
Time fences and possible actions
Firm Time
Volume DTF* PTF* End of Buckets
Fence
SOF SOS SOS

SOF
WOS WOS
SOF
WOF Flexible
WOF Free
WOP SOP SOP SOS
Frozen
SOP
WOF WOP WOP
WOS
2 to 3 weeks 8 to 12 weeks 16 weeks
Product Sites Requirements

General Parameter Parameters
* DTF : Demande Time Frence Firm horizon 2
* PTF : Planning Time Fence GPLNHOR 10 Day 60
Demand horizon 3
* LT : Lead Time Week 4
30 / © Sage 2010 OP203: Fundamentals Manufacturing Month 1
Work orders
Manufacturing > Planning > Work Orders
Main features of a work order

Project;
Lot;
• complete Source document;
• materials only WO designation
• operations only Default value
from product-site
Default value
Release Quantity & Unit Misc. from product-site
Site. Mode (Released) Information Routing
Order Product BOM Planning Alternate

status Code Information
(Released)
Scheduling mode;
• Planned
Start Date;
• Firm
End Date;
Priority

Exercise 2.2 – Create a work order

Understanding the decision tools
Priority planning – Capacity planning
Load/Capacity balance logic to complement the Demand/Supply balance logic
S&OP RRP*
Category Work centers
Product
MPS RCCP* Routing
Product site MRP CRP* Operation
Bill of Material
PAC Input Output
control
Demand
Load
Supply
* RRP : Resource Requirements Planning
Capacity
drives
* RCCP : Rough Cut Capacity Planning
* CRP : Capacity Requirements Planning constraints
Exercise 2.3 – Demand-Supply balance
inside the work order

Exercise 2.4 – Recalculate the loads

Exercise 2.5 – Load-Capacity balance
inside the work order

Understanding the Work Order printing logic
Learn about the WO shop packet content

Exercise 2.6 – Print the work order

Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

3. Common Data Management
The product category

Understanding the priority planning
The product
structuring 1/2
The product site
Understanding the capacity planning The Work center
structuring The routing
Understanding the priority planning
The bill of material
structuring 2/2
Defining concepts around common data Mass Changes to common data

Understanding the priority planning structuring
Product category
Product – category
Product – category
Rules Rules
Site
Product Product- Product-
data Site data Site data
Default value
Product-Site
Product
Product Product-
data Site data
/ © Sage 2010 Fundamental Inventory Sage ERP X3 v6

Focus on Stock management
SO* SO* SO* SO*
Available stock By order
WOS Link with order number WOS WOS
The order management strategy: the customer, its order number and the
project designation are kept on the orders

The category, Entry flows tab
Location Status QC entry
A default location can be If the document and/or The entry can trigger an
proposed during an the product definition analysis request
entry. The description don’t force the Q status,
(area) given by the a default status can be
column aims to make it proposed per entry
easy to find the good transaction
location type and/or the
location in the product
site
Management
rules
Lot entry
Lot by default
If the product is lot
A sales order or a work
managed we can control
order number can be
if the lot exists in the
used as the lot number
database

The category, Issue flows tab
Allocation rules Global locations
Stock lines determination Applied if a global

rules applied on Sales & allocation policy is used
Work orders
Issue flows
tab
Issue rule
Management rules
Stock lines determination
rules applied during Each movement type can
issues be customized

The category, Planning tab
Planning Manufacturing
Definition of horizons in Different lead times

order to manage time which have
fences consequences on the
end date and the start
date of the orders
Planning
tab
Reordering
Parameters
Depending on the
planner managing Depending on the
decisions, different reordering choices some
reordering rules can be data here are mandatory
set and adjusted

Exercise 3.1 – Product Categories Set Up

The product status
Active In Development Shortage Not Renewed Obsolete Not usable

Warning Warning Warning Warning
Entries KO
| message message message message
Issues | ------------------------------------Always OK------------------------------------
|
Bill of | Warning Warning Warning
OK OK
Material | message message message
| KO KO KO
WO Warning Warning
| (product not (product not (product not
(Component) message message
Always OK loaded) loaded) loaded)
WO (Parent | Warning Warning
KO KO KO
product) | message message
| Warning Warning Warning Warning
Sales orders | KO
message message message message
Purchase | Warning
| KO KO KO KO
orders message
|
MRP OK OK KO KO KO

The product, Identification tab Common Data/Product/Product
Miscellaneous Use
Individual information on Is the product submitted

the product to a lifecycle?
Identification
tab
Image
This image is stored in

the database

The product, Control tab
Inventory parameters
Recontrol/Expiration
The product, Tool bar
Inquiries
Functions
Costing

Exercise 3.2 – Product Set Up

The product site, Controls tab
Common data > Products > Product-Sites
Product site: Common data used to personalize the stock

management rules (location management, reorder policies) and
production rules on a given site
Quality
Sampling

The product site, Planning tab
Planning
Lead times
Reordering
Re-planning

The product site, Planning tab
EOQ (Economic Order Quantity)

Lot sizing

The product site, Stock tab
Internal stock situation

External stock situation
The product site, Totals tab
Entries
Issues

The product site, Calculated data tab
Entry data
Calculated data
The product site, Manufacturing tab
Routings
Parameter definition

The product site, Cost tab
Valuation Overhead cost

For all kinds of flow,
what will be the right Usable if the material or
valuation rule? the part or the sold good
has got indirect costs
Cost tab
Cost calculation
Manual entry for
components unless
calculation process is Unit price
launched using last price AVC, Last receipt cost &
for example. Calculated standard cost are
for produced goods. broken down into details

Exercise 3.3 – Product-Site Set Up

Understanding the capacity planning structuring
The Work Center
Head of work center

Controls tab
Variation tab
Replacement tab
Load tab

Exercise 3.4 – Work Center Set Up

The Routing
Head of routing
Header tab
Routings tab
Scheduling

Focus on routing and usefulness
Actual WO cost RCCP

roll up after
(MPS)
closing
Provisional Routing
and WO CRP
cost roll up
(MRP)
Load &
scheduling
calculation
during releases
62 / © Sage 2010
Exercise 3.5 – Routing Set Up

Focus on routings tab, detail operation – the different types of

time
Time set in the head of the routing
Time in hours Time in hours
Preparation Setup Run time Wait fixed

fixed fixed Proportional
Fixed or rate
Post Op fixed
Load time of the Work Center
Interoperation time
Load
Cost
Scheduling

The Bill of Material
BOM: describes the parent item
In order to configure and test it (design department)

In order to plan and create work orders
(planning department and workshop)
BOM: used for costing purposes
Planning BOM: making easier the forecast entries, considering

produced items of a family as components and the link quantities
(as a percentage) are the weight of the product inside the family
Used in MPS with a long horizon

Aims to analyse the MWS created by the dependent demand
(due to the planning BOM)

Parent-component relationship
Parent product
Where-used Link
x2 Coefficient = "Link quantity"
B Component

The levels
One level BOM Multi-level BOM

Alternate 11 Alternate 11
Level 0
B C Level 1 G H
B C
D Level 2 B

Phantom Bill Assembly A
Assy J Assy K Comp 1 Comp 2 Comp 3 Assy L Comp 12
Assembly A
Assy J Assy K Assy P Assy L Comp 12
Comp 1 Comp 2 Comp 3

Exercise 3.6 – Bill of Material Set Up

Defining concepts around common data
Mass changing to common data

Work Centers master data
Standard operations
Routing operations
Mass replace Work center
Mass application of capacity variation
Mass copy of routings
Can be restricted to operations on Work centers
where RCCP (Rough Cut Capacity Planning) = Yes
This is the only possibility to copy a Routing from one
site to another
Mass deletion of Routings

Exercise 3.7 - Cost roll up = global common
data verification

Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

4. Work Order Management
Managing the WO creations Managing orders in planning tools
Life of a firm Work Order

Understanding the WO content Product Lot
Scrap
Work Order & Scheduling
Lead time
Understanding the lead time & Cycle time, throughput time
scheduling Operation & material dates
Operation scheduling
Work order re-scheduled

Managing the WO creations
Introduction: Managing Orders in Planning tools, Action/Vision
Action Vision
Planning Workbench Individual Individual
Enterprise Planning Individual Multiple
Grouping Global Individual

WO can be generated from many different sources :
WO Shop packet
Suggestion (MRP, MPS, Reordering point, or periods)
Sales orders (Back to back, By order) Work orders Production Tracking
Material requirement (e.g. Semi Finished good)

Managing Orders in Planning tools, kind of orders and files
DEMAND SUPPLY
PORDERQ
Purchase
SORDERQ orders
SOF POF
Sales
orders
SOP POP PREQUISD

Purchase
requests
ORDERS
Forecasts
SOS ORDERS POS
Used for Reorder,
periodic or MRP
Planning & EOS WOS logics
MWS MSS
MRP logic
Inquiries
MWP MSP EOP WOP
MWF MSF EOF WOF
MFGITM
MFGMAT Work Orders Produced
Material
goods

Release of a firm Release of a Generation of a
Nature work order planned work suggested work Nature of orders
order order
Release
product
Parent product
WOF WOP WOS
of the BOM
By-
product
Component of
BWF BWP BWS
the BOM
Component
Component of MWF MWP MWS
the BOM
Opération Operation of the firm work (OWF)

routing
OWS order
Of the parent
OWF OWP Operation of the planned work (OWP)
order
product
ORS (OWS/ORS)
Load suggested in MRP/MPS

Managing Orders in Planning tools, Introduction
78 / © Sage 2010
Exercise 4.1 – Forecasts

Exercise 4.2 – Sales orders

Exercise 4.3 – MRP

Managing Orders in Planning tools
WO Transaction
Work Order Suggested
• From MRP & MPS Work Order Planned
• From ROP Work Order Firm
Work Order Planned
Direct release

Work Orders
Workbench & Data filtering
Data filtering
Workbench entry transaction Criteria button Formulas

Exercise 4.4 – Workbenches

Exercise 4.5 – Actions in Workbenches

Managing Orders In Planning tools, set up entry transaction
Authorized actions •Create/Modify WOP or WOF…
•Check users in products/product sites

By users •Users can be hidden
•General parameter GPLNFLT
Type of Orders displayed •SOF, SOP, WOS etc.…
Critical order •Formulas
Length of Actions •General Parameter GPLNHOR
Work Order Planned

Work Order Firm
Product Product site
Resource Orders

For an « ALL» entry transaction, the possible actions are
Planning Workbench Connection to Planning Workbench

Grouping Connection to Grouping
All Orders
Stock Inquiry Stock by site
Management data Set up & stock information on the product

Plan/Order Conversion into a Purchase order (P/F)

Plan/Initiate Conversion into a Work order (P/F)
Plan/Subcontract Conversion into a External order (P/F)

Associated orders View of the WIPs associated with the WO
zoom and connection to the planning workbench
WOS
Component Availability Component availability enquiry for the WO
Component availability Component availability by date enquiry for
by date the WO
Available to Promise Component available to promise enquiry for
the WO
Operation load If the WOS is scheduled

Modify/Initiate Modify the order or convert into a firm Work

order
Work Order Tunnel to the Work order
WOP
Scheduling Schedule functionality
Operation load If the WOP is scheduled
Modify Modify the order

Allocate Allocate the Work order
WOF
Assignment Assignment function
Operation load If the WOF is scheduled
For an « ALL » entry transaction, the possible actions are
Plan/Order Conversion into a Purchase order (P/F)
Plan/Initiate Conversion into a Work order (P/F)
Plan/Subcontract Conversion into a External order (P/F)

Associated orders View of the WIPs associated with the MW
zoom (pegging & horizontal dependencies) and
connection to the planning workbench MWF
Manual allocation The component can be allocated
Available to Promise Component available to promise enquiry for
the WO
Operation load Load of the linked operation scheduled
Multi-level planning Release of the product structure resources

Associated orders View of the WIPs associated with the SC
zoom and connection to the planning workbench SCP
Available to Promise Service available to promise enquiry for the
SC
Order Conversion into a Purchase order (F)

Associated orders View of the WIPs associated with the SC

zoom and connection to the planning workbench SCF
Available to Promise Service available to promise enquiry for the

SC

Understanding the WO content
Life of a Firm Work Order
Shop packet Tracking Close Costing
Pending Printed In Progress Completed Closed +

Costed
Being
Optimized
Optimized
Possibly
suspended

Lot Management
General parameter LOTMGT
In WOP
planning
LOT
In release WOF1 WOF2

LOT1 LOT2
At first Track1 Track2

tracking LOT1 LOT1
No (stock See Work order entry transaction if lot entered and entry
rules flow, movement type in the category: Lot entry and lot by
applied) default + Lot sequence number (Controls tab, product)

Scrap
I.e.: Quantity need Qn = 100, what is the Quantity to release Qr?
X3 formula Qr = Qn (1 + scrap)
Qn
APICS formula Qr =
(1 – scrap)
If Scrap factor = 50 %
Case 1 (ERP X3) : Qr = 150
Case 2 (APICS) : Qr = 200

Understanding the Lead Time & Scheduling
Lead time
Operation & material dates
Work order re-scheduled

Schedule
Not scheduled Scheduled Reschedule Optimized
Mark to reschedule

Lead time
Requested delivery date

Resource Start
date
Manufacturing/ Expected delivery date
Procurement Shipment date
lead time
Resource End date

Quality control Delivery lead time
lead time
Due date for X3

26/MM/YY 30/MM/YY
Routing operation 0
Operation LT 0
Order start date

Op 10 Op 20 Op 30 Op 40
Produced item
Material need date


Work order
26/MM/YY 30/MM/YY
Routing operation 0
Operation LT 1
Order start date

Op 10 Op 20 Op 30 Op 40
Produced item
Material need date


Work order scheduled only
26/MM/YY 30/MM/YY
Routing operation 40
Operation LT 0
Order start date

Op 10 Op 20 Op 30 Op 40
Produced item
Material need date

Operation Next Scheduling
operation
Op. 10 Op. 20 Overlapping
Op. 20 Op. 30 Start synch
Op. 30 Op. 40 Start synch
Op. 40 Op. 50 Successor
Op. 50

Work order re-scheduling
Schedule rules Parameters > Manufacturing > Scheduling

Schedule
Automatic Reschedule of arrears X
Date of SOF
process
WOS
Manufacturing
start date Backward scheduling by
overshooted default
WOS Automatic forward

102 / © Sage 2010
scheduling
Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

5. Capacity and Load
Understanding the capacity Capacity determination
Load determination
Understanding the Load
Load & Infinite Schedule

Understanding the Capacity
Capacity determination
General parameter:
Default weekly structure STO/SCH
Work Order PLNTWD
Parameters > Organizational Structure > Sites

Site Sites
Unavailable FR10
Work Centers
Weekly
SC1
Structures
WC No. of
2
resources
Capacity
variations

Understanding the Capacity
Capacity definition for a work center

Work Center 1, Number of resources = 4; 7 hours per day

Capacity is 28h / day
Day 1 2 3 4 5 6
Operation 23 hours in more than 3 days

on
Number of resources =1
WO1
Operation 17 hours in 2.5 days

on Number of resources =1
WO2

WO3


Day 1 2 3 4 5 6

on
WO1

WO2

WO3


Day 1 2 3 4 5 6

on
WO1

WO2
Operation 40 hours in
on 1.4 days
WO3 No. res =4
109 / © Sage 2010

Day 1 2 3 4 5 6

on
WO1

WO2
Operation 40 hours in
on 1.4 days
WO3 No. res =4
110 / © Sage 2010
Exercise 5.1 – Work Order generation,
preparation for firm load

Exercise 5.2 – Actions for priority planning
balance

Exercise 5.3 – Actions on load

Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

6. Modifying Work Order
Updating authorization
Understanding the possible actions Modifying components
inside the work order Modifying operations
Planning regeneration
Understanding tools to modify work
Available functions
orders
Understanding the dates Actions that have an impact on dates

Understanding actions inside the work order
Authorization: DEFWORTYP general parameter

Focus to a work order modification

Modifying components
Exclude/reactivate
Add
Replace

Modifying operations
Exclude/reactivate
Add
Replacement

Exercise 6 – Work order

Understanding tools to modify work orders
Available functions

Understanding tools to modify work orders
Available functions

Understanding the dates
Actions that have an impact on load & scheduling
•WO modifications that have an impact on operating loads

• Performing time tracking
• Load recalculation with re-scheduling
• Subcontract buying, considering the requested delivery date
• Transformation of a WOP in a WOF
• Manufacturing > Technical Data > Serial modifications > Work
center/Capacity variation
• Manufacturing > Batch processes > Work Orders > Upgrade

Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

7. Tracking
Tracking definition
Understanding the principles Personnel IDs
The single WO tracking
Time tracking
Production tracking
Understanding the workbench tracking
Material tracking
Reintegration

Tracking: Definition
Tracking
•Material
tracking
Work Order
• Pending
Transaction •Operation
• Printing tracking
• In progress
• Completed
•Production
tracking

Tracking : Entry transaction
•Back flush
Track Immediate materials •All
Manual issue •For manual components
Automatic determination •Allocation rules evaluated
•Closed
Not closed •All
•Reject Message
Miscellaneous •Personnel ID Tracking
•Message
•Material
tracking
Work Order •Operation

Category tracking
Product site
Transaction
•Production
tracking

Tracking : Manual
Manual

Tracking : Mass
Mass

Tracking without a Work Order
Tracking can be generated without a Work Order :
BOM tracking for Completed quantity or Material Tracking
Routing tracking for Time Tracking
Work Center tracking for Time Tracking
Time
Tracking
Work Completed quantity Mass closure/

Orders completions
(FUNTDUCLO)
Material Tracking

Tracking Combination
Tracking can be combined or done automatically
Time
Tracking
Work Completed quantity Mass closure/

Orders (Manufacturing plan) completions
(FUNTDUCLO)
Material
Tracking
Plan

Time tracking
Milestone and time tracking
Op No Milestone
10 No
20 Normal tracking
30 No
40 No
50 Range
Op 10 will never be tracked
Op 20 will be tracked alone
Op 30 and Op 40 will only be automatically tracked at the tracking of Op 50

Production Tracking
Main features of a work order tracking Manufacturing > Production tracking > Production tracking
Actual Labor WC;

• operations (start/end) Labor time set factor;
• status of closure Labor Run time factor;
Tracking Misc. Actual
Site. date Filter Information Set up time
WO Operation Actual Quantity Actual

number Tracking WC rejected Run time
Unit Status
Location;
Completed Tot. Achieved Misc.
Lot & Sublot;
Quantity Quantity Stock
Misc. Serial Number;
• operations (start/end) Info.
Stock Info. …
• material tracking mgt Quantity
• status of closure Filter tracked
Material Component Status

133 / © Sage 2010
Tracking OP203: Fundamentals Manufacturing
Time Tracking
Manufacturing > Production tracking > Time Tracking
Main features of a time tracking plan
End Date (start/end);

Work order (start/end);
Operation (start/end);
Released product (start/end);
Routing (start/end); Actual Labor WC;
• WO Labor time set factor;
Work center (start/end);
• Product Labor Run time factor;
…
• Miscellaneous
Actual
Misc. Set up
Site. Filter Time Type Operation Information time
ID Date Origin Actual WC Quantity Actual

rejected Run time
• WO Number
• Routing + Alt
• No origin

Exercise 7 – Work Order Tracking

Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

8. Work Order Close and Cost
Work Order close

Understanding the Work Order Close Mass closure
Work Order reactivation
Cost principles
(Theoretical) Provisional (BOM + Routing)
Understanding the Production costing Release Provisional (WOF)
Actual cost (Production Tracking)
Cost decomposition
Costing tools functions
Understanding Costing tools
Cost transfer

Understanding the 3 status fields of a work order
Order status
Release
Plan Release Close

Suggested Planned Firm Physical Process Closed
Life of a Work Order

WO shop
packet Tracking Complete Costing
Printed In Completed Closed &
Pending
progress Costed
Line Status
Tracking Close
Pending In Closed
progress

Closure
Product WO
Time Materials
Released Completed
Close
Close
Close
Close
Allocation
Load WOF
MWF
WIP
3 types of Cost
(Theoretical) Provisional (BOM + Routing)

Raw 1 Opé 1
Raw 2 Opé 2
Release Provisional (WOF)

Raw 1 ? Opé 1 Another Work Center used ?
Raw 2 Opé 2
? Raw 3
Actual cost (Tracking) +10

Raw 1 Opé 1 -½h
Raw 2 Opé 2
Raw 3

(Theoretical) Provisional Cost
(Theoretical) Provisional
TC/COS GPA/COS
CLCSTD*MAT CLCSTDRAT
GPA/COS GPA/COS
SCAMAJ EFFCSTUSE
GPA/COS
OVECOLSTD
Release Provisional
Actual cost

Cost Breakdown
(Theoretical) Provisional cost
Material cost
Comes from BOM
Labour cost
Comes from the costing dimension or from the Personnel IDs
Machine cost
Comes from the costing dimension
Sub-contracting cost
Comes from the costing dimension/operation price
General expense cost
Comes from material, product or costing dimension (Overhead)

Cost calculation : example 1
Unit cost Link Quantity Cost for
Quantity Total for 200
STK 200
Material
501-1 0.70 0.05 10 7.00
Machine
EDRILL Set 10.00 1 1 10.00
EDRILL Run 10.00 0.015 3 30.00
EPRESS Set 15.00 0.5 0.5 7.50
EPRESS Run 15.00 0.010 2 30.00
Labour
EDRILL Set 8.00 1 1 8.00
EDRILL Run 8.00 0.015 3 24.00
Total 116.50
Unit Cost 0.5825

Unit cost Link Quantity Cost for
Quantity Total for 100
STK 100
Material
501-1 0.70 0.05 5 3.50
Machine
EDRILL Set 10.00 1 1 10.00
EDRILL Run 10.00 0.015 1.5 15.00
EPRESS Set 15.00 0.5 0.5 7.50
EPRESS Run 15.00 0.010 1 15.00
Labour
EDRILL Set 8.00 1 1 8.00
EDRILL Run 8.00 0.015 1.5 12.00
Total 71.00
Unit Cost 0.7100

Release Provisional Cost
Release Provisional
GPA/COS TC/COS GPA/COS

CSTRCPORD VLTMATEXT MFCRATEXT
GPA/COS TC/COS
CLCWOCAUT VLTSEMEXT
Actual cost

Unit cost Quantity Quantity Cost for
Total for 100
100
Material
501-2 0.80 0.05 5 4.00
Machine
EDRILL Set 10.00 1 1 10.00
EDRILL Run 10.00 0.015 1.5 15.00
EPRESS Set 15.00 0.5 0.5 7.50
EPRESS Run 15.00 0.010 1 15.00
Labour
EDRILL Set 8.00 1 1 8.00
EDRILL Run 8.00 0.015 1.5 12.00
Total 71.50
Unit Cost 0.7150

Actual Cost
Release Provisional
Actual cost
GPA/COS
MFCRATCPL
Product site, valuation
method (Cost tab), see first
value “Valuation”
GPA/COS
OPRRATE
GPA/COS
OVECOLMFC

Exercise 8 – Close and cost

Understanding the Costing tool
WIP Finalization
• Monitoring & cost roll-up of orders costs
• Costing > Production costs > WIP finalization
WIP valuation
• Monitoring of costs for orders in progress
• Costing > Orders In Process > WIP valuation
Cost comparison
• Comparison between costs for one WO
• Costing > Performance Analysis > Cost Comparison
Multiple cost comparison

• Comparison between costs for WOs
• Costing > Performance Analysis > Multiple Cost Comparison

Cost breakdown
Product 1 Sub part 1
Sub part 1 Material
Machine Machine
Labour Labour
Overhead Overhead
Subcontract Subcontract

Course Contents
1. PREAMBLE
2. WORK ORDERS
3. COMMON DATA
7. TRACKING
9. APPENDIX

Appendix
Chapter and Contents
Chapter Contents
Common data General parameters & Activity Code
Work Orders General parameters & Activity Code
Work Order Management Flags and Updates

Common Data
BOM: Activity Code, General Parameter
CD
BOC TC/BOM
Activity Code General Parameter BOMLEV
CD
BOD TC/BOM
BOMSTE
CD
BOW
M
UML
I
LOT

Common Data
Routing: Activity Code, General Parameter
M GPA/ROU
Activity Code MFO General Parameter DEFWORTYP
GPA/ROU
ROUSTE
GPA/MIS
OPEEFFAPP
GPA/MIS
WSTEFFINH

Work Orders
WO: Activity Code, General Parameter
GPA/WOM
Activity Code M General Parameter CUMMAT
MFM
M GPA/CTL
MFI DOSFAB
GPA/MIS
M
LOTMGT
MFO

Work Orders
WO Modification: General Parameter
General Parameter Work Order
GPA/WOM GPA/MIS
RELUPD GRGENPLN

Work Orders
Workbench & General Parameters
General Parameters
STO/MIS STO/SCH
MFGMTSNUM GPLNFLT
Work Order
STO/SCH
GPLNHOR
ACH/AUZ
BUYFLT

Work Orders
Load/Scheduling: General Parameter
General Parameter GPA/LOA

SCHEDHOR

Work Orders
Tracking & General Parameters
Tracking
GPA/CTL GPA/CTL
CTLALL CTLFICTEC
GPA/CTL GPA/CTL
MTKALLMGT CTLOPEPRE
GPA/CTL
DOSFAB

Work Order management
Flags and Updates, Head of Work Order
Table Field LM Values Updates
MFGHEAD MFGSTA 317 1 = Firm 4 on WO Close

Order Status 4 = Closed
MFGTRKFLG 339 1 = Pending 3 on printing
Tracking flag 3 = Printed 4 on 1st tracking
or Situation 4 = In progress 5 when all details = 5
5 = Completed 6 on Final Costing
6 = Closed + Costed

Flags and Updates, Manufactured goods of Work Order
MFGITM MFGSTA 317 1 = Firm 4 on WO Close

Product Order Status 4 = Closed
ITMSTA 363 1 = Pending 2 on 1st tracking
Line Status 2 = In process 3 on Close in tracking
3 = Completed
MFITRKFLG 339 1 = Pending 4 on 1st tracking
Tracking flag 3 = Printed No change on full qty
4 = In progress without Close
5 = Completed 5 on Close in tracking
6 = Closed + Costed 6 on Final Costing

Flags and Updates, Components of Work Order
MFGMAT MFGSTA 317 1 = Firm

Material Order Status 4 = Closed
MATSTA 363 1 = Pending 2 on 1st tracking
Material status 2 = In process 3 on Close in tracking
3 = Completed
MFMTRKFLG 339 1 = Pending 4 on 1st tracking

Flags and Updates, Operations of Work Order
MFGOPE MFGSTA 317 1 = Firm 4 on WO Close

Operation Order Status 4 = Closed
OPESTA 308 1 = Pending 4 on 1st tracking
Operation Status 4 = In process 5 on Close in tracking
5 = Completed
MFOTRKFLG 339 1 = Pending 4 on 1st tracking

THANK YOU
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Who are you?

What are your expectations

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Installation Advanced Global Manufacturing

To be able to create a manufacturing data set.

To be able to manage the priority and capacity planning through

To understand all the possibilities in the manufacturing flow :

WO creation and modification

5 / © Sage 2010 OP203: Fundamentals Manufacturing

Sage ERP X3 Introduction (CB101)

6 / © Sage 2010 OP203: Fundamentals Manufacturing

Work Order Management

Capacity and Load

Modifying Work Orders

Work Orders close and cost

8 / © Sage 2010 OP203: Fundamentals Manufacturing

Chapter Objectives and Contents

Chapter Objectives Chapter Contents

Understanding the CIM (Computer Integrated

Understanding the priorities analysis The planning sequence

Introduction to Volume-Variety illustration

9 / © Sage 2010 OP203: Fundamentals Manufacturing

10 / © Sage 2010 OP203: Fundamentals Manufacturing

PLANNING MATERIAL DRIVEN CAPACITY DRIVEN

2 PRIORITY PLANNING CAPACITY PLANNING

3 CAPACITY PLANNING MATERIAL PLANNING

* S&OP : Sales & Operations Planning

16 / © Sage 2010 OP203: Fundamentals Manufacturing

Demand lead time constraints and cumulative lead time

ETO MTO ATO FTO MTS

ETO : Engineer To Order

18 / © Sage 2010 OP203: Fundamentals Manufacturing

21 / © Sage 2010 OP203: Fundamentals Manufacturing

Chapter Objectives Chapter Contents

22 / © Sage 2010 OP203: Fundamentals Manufacturing

Demand analysis Feedback

23 / © Sage 2010 OP203: Fundamentals Manufacturing

24 / © Sage 2010 OP203: Fundamentals Manufacturing

* BOM : Bill Of Material Work Order

Single Single WO Single WO Single WO Single WO Single WO Single WO Single WO

WO WO Stock Load WO shop Time Material Completed Qty Closure/ Costing

Automatic Automatic Automatic Automatic Automatic Automatic

26 / © Sage 2010 OP203: Fundamentals Manufacturing

Work Manufacturing Plan Mass closure/ WIP

Material Tracking Plan

and Work Orders Production tracking Work Order Close WIP

27 / © Sage 2010 OP203: Fundamentals Manufacturing

S&OP : The forecast values and requirements from the sales

MPS : Master Schedule items are planned (those items that

28 / © Sage 2010 OP203: Fundamentals Manufacturing

Plan Release Close

Life of a Work Order

29 / © Sage 2010 OP203: Fundamentals Manufacturing

SOF SOS SOS

Product Sites Requirements

Main features of a work order

Order Product BOM Planning Alternate

31 / © Sage 2010 OP203: Fundamentals Manufacturing

32 / © Sage 2010 OP203: Fundamentals Manufacturing

Product site MRP CRP* Operation