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June 2013

Written by Richard on June 13, 2013

Be careful when using the Material Requirement Part Replace function

The Material Requirement Part Replace function is a great feature of VISUAL when you have to replace a large number of requirement cards for the same Part ID with a new one.

Infor VIUSUAL ERP - Manufacturing Window
The REPLACE feature can be found under the EDIT menu of the Manufacturing Window

If you need to do a mass update, you can selectively replace Part IDs across Eng Masters, Quote Masters and/or Work Orders.  This function also allows you to change quantity (Qty Per, Fixed, Scrap) and cost information during the replacement process.
 
Infor VISUAL ERP - Manufacturing Window
The Material Requirement Part Replace window.

 

So this feature can save you a lot of time and effort

BUT it can also cause you a lot of grief if you're not careful.

First of all, I'm sure you're aware that this feature has the potential to modify a significant number of material requirements (especially if you hit the "REPLACE ALL" button) - so proceeding with caution is warranted

What you may not know is that this has the potential for causing major delays and issues the next time you run costings!  Say What?

This feature, if not carefully used, will allow you to replace materal cards on CLOSED work orders if the material card is UNISSUED (regardless of the cards' status).  And because of the way VISUAL works - these work orders will then have their POSTING CANDIDATE set to YES and will be re-assessed by the costing utilities.  Whoa!

This issue only applies to replacing parts on work orders.  So be very sure before you commit to replacing parts on a large number of work orders - especially if you hit the "REPLACE ALL" button

The Material Requirement Part Replacement window is definitely missing a much needed filter (or column) --> Work Order Status.  That or only show orders that are FIRMED/RELEASED.  This would be a great Enhancement Request.

Written by Jason on June 5, 2013

Sweep the Leg

 

VisualNuggets.com
Sweep The Leg

There’s always that big debate of whether to use leg and detail and having one complex engineering master, or breaking it up into layers.  From the recent projects I am working on, the latter is working out excellent.

 

Here’s how we use Easy lean to simplify our builds, simplify planning, and reduce inventory on the floor. 

We had many complicated builds using a lot of leg/detail.

Here is an example of an engineering master that goes 6 fabricated layers deep comprising of 50 sub IDs (legs).

  • Top layer – 1 final assembly
  • 2nd layer – 5 sub IDs
  • 3rd layer – 8 Sub IDs
  • 4th layer – 10 Sub IDs
  • 5th layer – 12 Sub IDs
  • 6th layer – 14 Sub IDs

We broke out each of these Sub IDs as make-to-stock parts.  As an order was created for the top level part, Easy Lean would go through the requirements and create firmed work orders with appropriate release dates for each.  Release dates for each part is calculated by the parts “buffer”.  The Buffer is basically the time it takes to complete that work order.  In the example above, here are the buffers we assigned to each layer:

  • Top layer – 1 final assembly - 4 day buffer
  • 2nd layer – 5 fabricated parts – 5 day buffer
  • 3rd layer – 8 fabricated parts – 3 day buffer
  • 4th layer – 10 fabricated parts – 2 day buffer
  • 5th layer – 12 fabricated parts – 3 day buffer
  • 6th layer – 14 fabricated parts – 2 day buffer

When you calculate out the buffers and how the “layers” will be released it would look something like this:

Infor VISUAL ERP - Buffer Easy Lean

Notice we only gave the shop floor what they needed.  Instead of 50 work orders (sub IDs) getting printed and released all at once; the work orders were released in ‘layers’.  No human intervention was required in the planning of things as Easy Lean planned it all.  We could also set up replenishment levels and min/max/multiple rules in Part Maintenance for each make-to-stock part and plan all those to stock.

There are many other benefits of Easy Lean but what I find the most beneficial is this “MRP automation” it can do.  As long as you can define the logic it needs to follow, Easy lean will do all the planning for you!


Jason Snoeyink is a frequent contributor to visualnuggets.com and is an active participant in the VISUAL community. 

Connect with him online at LinkedIn