Creating and Releasing Work Orders in QAD PDF

Page 1 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Rele...

Page 1 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 1. Purpose: To define the process for creating, changing, and releasing work orders in QAD. 2. Scope: Work Orders are responses to demands for materials that are usually generated by Material Resource Planning (MRP), but can be entered manually in Work Order Maintenance. Work Orders control and monitor the progress and cost of manufacturing. 3. Responsibilities: 3.1. Business Unit Leader is the owner(s) of this process. 3.2. Supervisors and Production Admins are responsible for creating work orders. 4. Reference Documents and Forms: 4.1. Rework/ Sort Work Instruction (Document# 1293) 4.2. Rules for Product Lot Numbering (Document# 3491) 5. Definitions: 5.1. Rework – an operation performed on non-conforming products in order to make those products conform to customer specifications. 5.2. Sort – an operation performed on non-conforming products when a rework is impossible or unnecessary to ensure products conform to customer specifications. 5.3. ERP – Enterprise Resource Program 5.4. QAD – Putnam Plastics Corporation’s (PPC) ERP system. 5.5. Work Order – a document driving the manufacture of finished sellable goods or subparts of finished goods from raw materials. 5.6. Work Order Status Code – A representation of the state of a work order in the work order life cycle. 5.7. Status Code “P” (Planned) – This work order has been planned by MRP, the ERP will adjust this work order as necessary. 5.8. Status Code “F”(Firm Planned) – The work order has been scheduled for production. The order will not be changed by the ERP and must be manually modified. 5.9. Status Code “A”(Allocated) – The work order has been scheduled for production and material can be reserved against this order. 5.10. Status Code “R” (Released) – The work order is actively in production. Work is currently happening on the order or will happen soon. 5.11. Status Code “C” (Closed) – The work order is complete and all activity against a work order is recorded in the system. 6. Safety Precautions: N/A 7. Process: 7.1. Firming Planned Work Orders 7.1.1. Planned work orders are suggestions by the system to manufacture product for a defined inventory need. QAD automatically adjusts planned work orders based upon current material requirements. These adjustments may include, but are not limited to, the work order start date and quantity. 7.1.2. The firming process is an acknowledgement of material requirement and prevents automatic adjustments by the system. 7.1.3. To Firm a planned work order in QAD, navigate to “23.10 Planned Work Order Approval” Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 2 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.1.4. Enter appropriate information into the following fields, not all fields are required 1. Item Number – Enter a range parts to approve 2. BOM/Formula – Enter a range of Bills of materials to approve 3. Site – Enter the site where the production will occur, ususally 2000 4. Release Date – Enter a date range to select orders to be released within the range 5. Default Approve – Sets the default action for the approval screen 6. Buyer/Planner – Only show work orders for a specific planner 7. Include Phantoms – Checked 8. Include Line Manufactured Items – Checked 9. Include Purchased Items – Unchecked 7.1.5. Press Next 7.1.6. Unselect any work orders that should not be processed (Note, if the default approve was not checked, then select work orders that should be processed). 7.1.7. Click Next, the system will change the work order status from “P” to “F” for all the selected orders. If the search criteria returned more than 10 orders, the next group of 10 orders display on the screen. 7.1.8. When finished Firming Orders, click Back Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 3 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.2. Releasing Existing Work Orders: 7.2.1. Navigate to 16.1 Work Order Maintenance in QAD. 7.2.2. Enter work order ID number. 7.2.3. Verify the Item Number, Description, Quantity Ordered, Order Date, Release Date, Due Date, Routing Code, and Site are correct. 7.2.4. Select theWork Order Status field and replace the current status with “R”, and press enter or Next. 7.2.5. In the Work Order Attributes enter the lot number from the Work Order Cover sheet and click Next. Use Rules for Product Lot Numbering (Document #3491) to determine if the automatic lot number assigned needs to change 7.2.6. Select the correct Purpose for the Work Order and press enter or click Next. (Enter the applicable Prompts which vary by Purpose) Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 4 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 1. INHOUSE (In-House Order)- the user is not prompted for a sales order and the Sales/Job field is populated with INHOUSE. 2. PRODUCTION (Production Order)- the user is prompted to enter a sales order number and sales order line number which populates the Sales/Job field. 3. R&D (R&D Order)- the user is prompted to enter a sales order number and sales order line number which populates the Sales/Job field. 4. RESEARCH (Research Order)- the user is prompted to enter a Project code. 7.2.7. DO NOT CHANGE ANY OF THE ACCOUNTING DATA. Press Enter 1. Once the screen changes from the Accounting Data press the “Back” button on the screen. Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 5 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.3. Creating a New Work Order: 7.3.1. Navigate to 16.1 Work Order Maintenance in QAD. 7.3.2. Press the “Enter” key, QAD will assign a Work Order Number and Work Order ID number automatically. 7.3.3. In the “Item Number” field, type the applicable Item Number. 7.3.4. Leave the “Type” field blank (QAD will release an order with a blank field type as a standard work order). 7.3.5. In the “Site” field, enter 2000 for Putnam Plastics. Press the ENTER key. The cursor will drop down to the “Quantity Ordered” field. 7.3.6. In the “Quantity Ordered” field, type the number of units required for manufacture. 7.3.7. The “Order Date” field identifies the date the work order was entered. 7.3.8. Use the “Release Date” field to identify and enter the date a work order is scheduled for production. 7.3.9. Due Date defaults to today’s date plus the manufacturing lead time for the item. This is the date a work order is due to be completed. 7.3.10. In the “Work Order Status” field, type in “R” if the work order is ready for production, otherwise type “F”. 7.3.11. Ensure the “Routing Code” has the same data as the “Item Number” field. 7.3.12. Click Next or Press Enter. 7.3.13. In the Work Order Attributes enter the lot number from the Work Order Cover sheet. Use the Rules for Product Lot Numbering (DocumentDocument #3491) to determine if the automatic lot number assigned needs to change. Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 6 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.3.14. Select the correct Purpose for the Work Order and press enter. (Enter the applicable prompts which vary by Purpose). 1. INHOUSE (In-House Order)- the user is not prompted for a sales order and the Sales/Job field is populated with INHOUSE. 2. PRODUCTN (Production Order)- the user is prompted to enter a sales order number and sales order line number which populates the Sales/Job field. 3. R&D (R&D Order)- the user is prompted to enter a sales order number and sales order line number which populates the Sales/Job field. 4. RESEARCH (Research Order)- the user is prompted to enter a Project code. 7.3.15. DO NOT CHANGE ANY OF THE ACCOUNTING DATA. Press Enter Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 7 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 1. Once the screen changes from the Accounting Data press the “Back” button on the screen. 7.3.16. If a specific lot of raw material needs to be reserved for the work order, see section 0. 7.3.17. The work order is now created and active. To print the work order, see section 0. 7.4. Creating a Sort or Rework Work Order 7.4.1. Navigate to 14.15.1 Alternate Routing Maintenance in QAD 7.4.2. Enter the following information in the specified fields:  Item Number -type the applicable Item Number  Site- enter 2000 for Putnam Plastics and press “Enter” key. 7.4.3. In “Routing Code” field, type “rework/sort” and press the “Enter” key. 7.4.4. In “Bill of Material” field, type the “Item Number” and press the “Enter” key. Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 8 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.4.5. Close the Alternate Routing Maintenance screen. 7.4.6. Navigate to 16.1 “Work Order Maintenance” in QAD. NOTE: this order will process similar to a “Manual” work order 7.4.7. Press “Enter” key, QAD will assign a Work Order Number and Work Order ID automatically. 7.4.8. In the “Item Number” field, type the applicable Item Number. 7.4.9. In the “Type” field, enter an “R”, this signifies the work order is a rework/sort order. 7.4.10. In the “Site” field enter “2000” for Putnam Plastics and press the Enter key 7.4.11. In the “Quantity Ordered” field, type the number of units required for sort or rework. 7.4.12. Enter the order date, release date and due date in appropriate fields. 1. Order date identifies the date the Work Order was entered. 2. Release date defines the date the work order is scheduled to be sorted or reworked 3. Due date is the date a work order is due to be completed. 7.4.13. In the “Work Order Status” field, type in “R” 7.4.14. In the “Routing Code” field enter “rework/sort” and press enter. 7.4.15. In the “Bill of Material” field, select the BOM code, that corresponds to the “rework/sort” routing code. 7.4.16. In the ‘Lot/Serial” field enter the rework or sort product lot number and press the “Enter” key. For In House Orders example: Rework or Sort orders will contain only the original lot number ex. 3112345 (No “R” or “S” added) For Customer Return example:  For rework append an “R” to the end of lot number ex.3112345R  For sort append an “S” to the end of lot number ex. 3112345S Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 9 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.4.17. In “Purpose” field : 1. For In House orders: select INHOUSE (In-House Order) and press “Enter” key twice. 2. For Customer Returns: Select PRODUCTN (Production Order) and press “enter” twice. 7.4.18.Reserve the reworked product lot number for the work order using section 0 The rework work order is now created and active. To print the work order, see section 0 Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 10 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.5. Work Order Bills of Material (BOM) 7.5.1. Each Work Order in QAD has a unique bill of material that is a copy of the product structure at time of work order creation. Occasionally, it is necessary to add or remove components from a work order. 7.5.2. To Add/Remove materials, navigate to 16.13.1 Work Order Bill Maintenance 7.5.3. Enter the either the Work Order number, ID, or both fields and click Next. 7.5.4. Use the up/down arrows on the keyboard to scroll through the existing components. 7.5.5. If necessary, add a new component by typing the part number in the “Component Item” field. 7.5.6. Enter the operation where the material should be consumed as necessary, 7.5.7. Click Next 7.5.8. Enter the total quantity required to produce the total amount of the parent in the “Quantity Required” field. 7.5.9. Enter the quantity required to produce one unit of the parent, in the “Qty Per Unit” field.Note: this field is necessary to consume material at time of production. 7.5.10. Click Next to save the record. 7.6. Reserving Raw Material for a Work Order 7.6.1. Materials can only be reserved for a work order if the order status is Released, Exploded, or Allocated. 7.6.2. Navigate to 16.4.1 Work Order Material Reservation in QAD. 7.6.3. In the “Work Order” field, type the work order number and press the ENTER key. 7.6.4. A window will appear showing the bill of materials of the work order and the required amount of each material. Use the UP and DOWN arrow keys on the keyboard to navigate the “RSV” column on the left side of the window. Press the ENTER key while highlighting the desired lots to reserve them. 7.6.5. Press F1 on the keyboard to save the reservations. 7.7. Printing the Work Order Packet 7.7.1. Navigate to 16.6 Work Order Release/Print Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 11 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 7.7.2. Type the Work Order Number in the Work Order field and click Next (or press Enter) 7.7.3. Type the ID in the ID field and click Next. 7.7.4. Click the checkmark for the following options 1. Print Picklist 2. Print Routing 3. Print Co/ByProducts 4. Operation 7.7.5. Click Next or Press Enter 7.7.6. In the popup, leave the selections as is and click Next 7.7.7. Type an output device (printer/screen option) in the Output field, and click Next 7.7.8. The system will process the request and print to the selected device. Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15  Page 12 of 12 Document Revision: Document Name: Number Effective Date: 1780 4 Creating and Releasing Work Orders in QAD 04-04-16 8. Revision History: Revision Number Date Explanation Including ECO /CCO Number 01 8/27/12 ECO#01038-Updatedbformat and added Document number 02 10/03/13 ECO#02255- Complete rewrite 03 05-09-14 CCO#02810 - added how to create rework/ sort order CCO# 522 – added definitions for work order, work order status code, status code P, status code F, status code A, status code R, and status code C. Updated process. Put in 4 3-18-16 newest template. Previous Revisions See revision history file in Document Control Proprietary and Confidential This Document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express written authorization is prohibited Property of Putnam Plastics Corporation and its associated departments. General Work Instruction Template – #2419 Rev 4 Effective Date: 10-07-15