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Chapter 10: Use and Design of The Production Control Module: Objectives
Chapter 10: Use and Design of The Production Control Module: Objectives
Chapter 10: Use and Design of The Production Control Module: Objectives
Introduction
Production control in Microsoft Dynamics AX 2012 consists of many aspects of
the production environment. This includes creation, estimation, scheduling,
consumption, feedback, and cost accounting for production orders.
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The major processes of the Production control module are shown in the
following figure.
In this chapter, you will review the following major components of the
Production control module.
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Bill of Materials
A bill of materials (BOM) is a complete list of all the components, parts, raw
materials, assemblies and their quantities that are required to make a finished
product.
BOMs define the relationship between the components and the finished product
or sub-assembly. The item number that represents the BOM is often referred to as
the finished product, and the components that make up the finished good are
referred to as raw materials. In some cases the item number that represents a
BOM is not a finished good and is instead referred to as a sub-assembly which is
used in another BOM to create a finished product or another sub-assembly. A
clear definition of this relationship is important for the following.
• Allocation of materials
• Scheduling of operations or jobs
• Creation of production orders
• Costing of the BOM and production order
Every item that must be physically accounted for in a finished product or sub-
assembly product or financially accounted for in the costing phase must be
included in the BOM. Although BOMs define the components and their
relationships, they do not define the sequence of steps to produce or assemble the
finished item.
BOMs are made up of product types, versions, configurations, sites, levels, lines,
and information used for cost calculations. In the following sections, these
components and the data model for BOMs are reviewed to illustrate the
relationship between the tables.
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BOM Version
A BOM can have multiple versions. When you create a BOM, you must have at
least one version. In order to use the BOM it must be approved and activated.
Later, if the BOM is no longer required, the activation and approval can be
removed. The BOM version is used to define which finished product item
numbers are linked to the BOM. You can also specify information about the date
of validity, site, quantity ranges, whether the version is active, and who approved
it.
Zero or more BOM versions can be valid or active for any item at any given
point in time. However, only one version can be applied. The applied version is
selected based on time, site, and quantity. The BOM version is useful in these
cases.
• Two products that consist of the same raw materials but different
production processes will be able to use the same BOM but different
routes. For example, the same product is produced in two different
sites by using different equipment.
• When changing the raw materials of a product over time, different
BOMs can be attached as of a specific date. In the example of the
personalized coffee mug, the paint that is used for the mug was
originally paint X, and now they are going to use paint Y to make the
mugs. This change can be reflected in a new BOM version as of the
date that the change occurs.
BOM Configuration
For planning, calculation, and consumption purposes, each BOM line must
specify whether the item has any configurations. A configuration is a standard
component combination, such as a satellite speaker and a sub-woofer that can be
specified for a BOM item during the ordering process. For example, the user
might select the size and color of speaker to be included in the home theater
system.
A finished product can be set up so that parts of the finished good can be
produced at different production sites. A typical scenario for production at
multiple sites might involve an end item that includes component items, where
the component items are produced at and moved between different sites, and the
sites share common item numbers. Each BOM version can be linked to a specific
site, or each line of BOM can have a different site assigned.
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BOM Levels
BOMs can contain many levels of goods to produce. A simple BOM is all on
level one. For example, when assembling a cabinet, you will have the frame,
shelves, and hardware. These are all on the same level, because each primary
component is in the assembly.
The lines in the BOM are the individual items or services that make up the BOM.
Each product has its own BOM line. An unlimited number of lines or items can
make up the BOM.
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BOM Costing
Bills of material calculations use data from several sources to calculate the
rolled-up or total costs of a manufactured item. The sources include information
about items routing details, indirect cost calculation formulas, and the costing
version. The purchased item information that is used in a standard cost BOM
calculation includes cost, cost group, and warning conditions.
The bill of material information that is used in a standard cost BOM calculation
depends on the following.
• BOM version
• BOM line item quantity
• BOM line item scrap
• BOM line item valid dates
• The default order type of the BOM line item
• Parameters for the cost calculation
• Sub-route for a manufactured component
• Effect of operation scrap percentages
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The following figure shows the relationship between the BOMTable, BOM and
BOMVersion. These do not include all the available fields for the tables, because
of size limitations and relevance.
The BOMTable is the primary table of the construct. Contained within is the
setup for a Bill of Material, including Approved, BOMId, Name, Version, and
SiteId. This is best described as the header information that you must define for
the BOM. For example this is an Eight inch woofer speaker assembly.
The BOM is the line items associated with the primary table. You can have many
line items that are related to each BOMTable. Each BOM record is related to one
InventTable record to create the link for the components to the raw materials
items and services. For example, the woofer speaker assembly might include the
speakers, cabinet, and cross over assembly needed to construct the speaker. For
the speaker assemblies, they can be used for other cabinets or other
configurations.
The BOMVersion is the final table needed for the basic BOM set up. The
relationship between the BOMTable and BOMVersion is one or more versions
for each BOM. Each BOMVersion record is related to one InventTable record to
create the link to the finished product item number. For example, one version
could be used for one site and a different version for another site. Frequently
BOMs are phased out, with new components that are included in the latest
version.
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The ProdBOM table is used to store the production ready, approved BOM. It is
copied from the original BOMTable (header) and BOM (lines) tables. This
follows the goods being produced throughout the life cycle of the product. This
design allows users to modify the BOM for a specific production order without
affecting the original BOM definition. Frequently it is referred to as the product
revision. From this all items or services are picked, assembled, quality assured,
reported as finished, and ended.
Routes
Routes are the path or sequence that the product takes from operation to
operation, starting with the beginning of the production process and continuing to
the end. It is a set of sequential operations, or tasks, that are required to produce a
product. The route operations describe the requirements for the resources that are
required for performing each operation. Each route includes the following:
• Operations to be performed.
• Operations relations.
• Sequence of the operations.
• Resources requirements involved in completing the operations.
• Standard times for the set up and run of the production.
One or more routes can be mapped for each product, depending on the product
and the process. You can create a completely new route, or you can base a new
route on existing route information, and then adjust or update the information to
match the new production process. The same route can also be used for multiple
products.
In the following section, you will review how to use routes and operations and
the data model associated with them.
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Operation Relations
Sequence of Operations
Operations in a route must be attached to each other in a logical way to reflect the
production process. Depending on the complexity of the production, this can
result in a route network. For simple routes, where the operations are executed
one after the other, a route network is not required.
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Also important for this model, is the relationship between Routes, ReqRoute, and
ProdRoute tables. For example, a regular route includes how the task or activity
is completed, the order and operation priority, and the requirements for the
resources that will perform them. The ReqRoute table is primarily populated
during master planning to record which operations are used for a production
order, and when the planned order is firmed. This data is then combined with the
operation relation to make up the production route in the ProdRoute table. This
makes sure that the route does not change mid-process and still allows planners
and schedulers to be able to update the Route table. The route on a specific
production order can be modified; much like a BOM can be, without affecting
the original route.
Production Orders
The production order contains information about what is to be produced, how
much (quantity), and the planned finish date. The system assigns an order status
to each step in the life cycle of the order. The status shows where the item is in
the production process.
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If the vendor's capacity is not scheduled, do not attach the route for the sub-
BOM. When no route is attached, the delivery time for the sub-BOM is taken
from the component items released products' base data.
If you want to schedule the vendor's capacity, create the route for the component
item and specify Vendor as the resource on the appropriate lines.
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The first status of a production order is Created. When a production order has
this status, you can edit the production's BOM and route. However, changes to
the production's BOM or routes when it has any status other than Created, require
that the previous update jobs be run again. For example, if you make changes in a
BOM or route for a production in which the status is Released, then the prior
steps Estimated and Scheduled must be run again. Not all steps are required for a
production order. The steps that are required are based on the configuration of the
Production control parameters.
The following topics provide a review of the production control steps, with an
emphasis on how each step applies to financial journals and the interaction with
the general ledger.
Step 1 – Created
When you create production orders, you can specify the settings that determine
how production order transactions are posted to the ledger. These settings apply
to production orders created manually or automatically from a sales order or
master planning schedule.
Step 2 – Estimated
This step involves the calculation of the most likely material and labor for the
production. The system creates inventory transactions that are issue transactions
for raw materials with the status of On order and receipt transactions for the
BOM with the status of Ordered. In some cases, the system will create purchase
orders and subproductions for the production order. Items are reserved and the
prices of the finished goods are calculated based on parameter settings.
Step 3 – Scheduled
The third step in the production order life cycle is Scheduled. Production orders
can be scheduled based on operations scheduling or job scheduling.
Step 4 – Released
In this step, the system releases the production order when the schedule is
realistic. At this point, you can print production order documents such as the job
card and the route card. Now, the status of the production order changes to
Released and indicates that the production can start.
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Step 5 – Started
When a production order is started, you can post costs against the order. You can
automatically allocate estimated material and route costs to the order when it is
started. This allocation is known as forward flushing or auto consumption. You
can manually allocate material to the order by creating picking list journals. You
can also manually allocate labor and other route costs to the order. If you use
operations scheduling, you can allocate these costs by creating a route card
journal. If you use job scheduling, you can allocate these costs by creating a job
card journal.
When the production order is reported as finished, the quantity of finished goods
completed is updated in the Inventory and warehouse management module. If
you use work-in-process (WIP) accounting, the system uses the standard cost
from the On-hand form to create a ledger journal to reduce the WIP accounts
and increase the inventory of the finished goods.
If the material and labor costs associated with the production are not already
allocated in a journal or by forward flushing, they can be automatically allocated
by back-flushing. This involves the post-deducting of inventory transactions
processes.
Step 7 – Ended
Before you end production, the system calculates the actual costs for the
produced quantity and all estimated costs of material, labor, and overhead are
reversed and replaced with the actual costs. If you select the End job check box
when you run the cost calculation, the production order status changes to Ended.
This status prevents any additional costs from being unintentionally posted to a
completed production order.
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The ProdTable is the primary production order table, which contains the header
information about all of the production orders. Each production order contains is
related to at least one InventTransOrigin and InventTrans table record. Each
production order can be connected to a planned production order, a sales order or
a project.
When a production order is created from master planning, the planned production
order is stored in the ReqPO table. The ProdTableProj table contains information
about production orders that belong to projects. Such a production order is
connected to a real production order stored in the ProdTable table and to a project
stored in the ProjTable table.
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Production journals are located by opening Production control > Common >
Production orders > All production orders. Click the View tab in the Action
Pane, and then you can view the journal types in the Journals group. The
production journal types include the following.
Production journals consist of two main parts—the journal header and the journal
lines, or actual journal records. Journal lines reflect the actual records or entries
present in the journal. These records can include a list of production materials
ready for release, the time consumed, the number of good and defective items,
and so on.
ProdMulti
You can update production orders one at a time or update multiple orders one
time. You can use the RunBaseMultiParm structure to run different parameter
(parm) tables that use the same structure. The ProdMulti class is the base class
that you can use to update production orders. It is based on the
RunBaseMultiParm class. A user interface (UI) should be implemented for
derived classes.
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Syntax:
From the base UI form, it makes a call to ProdMulti for all updates. For example,
updating to Estimated calls ProdMultiCostEstimation::main().
if (_args.parmEnum() == RunChoose::Run)
{
prodMultiCostEstimation =
ProdMultiCostEstimation::construct(_args);
RunBaseMultiParm::initFromForm(prodMultiCostEstimation,_arg
s);
if (! prodMultiCostEstimation.prompt())
return;
prodMultiCostEstimation.runOnServer();
prodMultiCostEstimation.refreshCaller(_args);
}
else
{
RunBaseMultiParm::runSpecial(_args);
}
/// <summary>
/// Initializes an instance of the <c>RunBaseMultiParm</c>
class by using a container of packed records.
/// </summary>
/// <param name="_includeRecords">
/// A Boolean parameter that indicates whether records are
included.
/// </param>
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container _packedRecords)
{
Common common;
int recordCounter;
ParmBuffer parmBuffer;
if (_includeRecords)
{
parmBuffer = this.defaultParmBuffer();
parmBuffer.Linenum = 0;
All selected records in the form data source are added to the appropriate parm
table. If the update is called from the main menu, there is no data source and no
records are found.
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if (_args.parmEnum() == RunChoose::Run)
{
prodMultiCostEstimation =
ProdMultiCostEstimation::construct(_args);
RunBaseMultiParm::initFromForm(prodMultiCostEstimation,_arg
s);
if (! prodMultiCostEstimation.prompt())
return;
prodMultiCostEstimation.runOnServer();
prodMultiCostEstimation.refreshCaller(_args);
}
else
{
RunBaseMultiParm::runSpecial(_args);
}
The prompt displays the form where the user can change the settings to update
the order. There is also a Select button on the form that the user can click to
modify the query and select more records. When the form is opened from the
main menu (Production control > Periodic > Production orders), the query is
empty and the user must click this button to select the records for update.
...
while (curParmCostEstimation)
{
try
{
prodTable =
this.initProdTable(curParmCostEstimation.ProdId);
prodTable.status().runCostEstimation(curParmCostEstimation,
false,prodPurch,this);
}
catch (Exception::Deadlock)
{
retry;
}
...
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next curParmCostEstimation;
}
}
All records in the parm table are looped over. The ProdStatusType sub-class is
instantiated by using the status of the prodTable record, then the update is called.
ProdStatusType
Production order updates are controlled by using the ProdStatusType class and
subclasses.
Each stage of the update process must occur. If the current status of an order is
Estimated, and you try to update it to Report as Finished, then it must be
Scheduled, Released, and Started before it can be reported as Finished. The
required status and status sequences are configured in the Production control
parameters form.
Before each update is run, the system checks to determine whether the previous
status is already processed. If the update is not installed, then the system runs that
update. It also handles which updates can occur with a production order. For
example, a production order with the status Finished, cannot be Estimated.
1. View ProdMultiReportFinish.Run().
...
while (prodParmReportFinished)
{
try
{
this.initProdTable(prodParmReportFinished.ProdId).status().
runReportFinished(prodParmReportFinished,false,this);
}
catch (Exception::Deadlock)
{
retry;
}
...
next prodParmReportFinished;
}
}
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2. View ProdStatusType.runReportFinished().
...
if (!_ask)
{
if
(this.shouldRunPreviousJob(ProdStatus::ReportedFinished))
{
ProdUpdReportFinished::runPreviousJob(
_prodParmReportFinished,
_multi);
}
prodTable.type().runReportFinished(
_prodParmReportFinished,
_multi);
}
return true;
...
ask is set to true only when the method is called to ask whether the update is
allowed, not to run the update.
3. View ProdUpdReportFinished::RunPreviousJob.
prodParmStartUp.insert();
ProdTable::find(prodParmStartUp.ProdId).status().runStartUp
(
prodParmStartUp,
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false,
null,
_multi);
}
if (!_ask)
{
if (this.shouldRunPreviousJob(ProdStatus::StartedUp))
{
ProdUpdStartUp::runPreviousJob(
_prodParmStartUp,
_prodPurch,
_multi);
}
prodTable.type().runStartUp(
_prodParmStartUp,
_multi);
}
return true;
Because the previous status to Started is released, and because this order is
already released, it is not necessary to run the previous job.
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ProdUpd
The ProdUpd class is the base class of production classes used to update the
production order status. The following figure shows the class hierarchy for the
ProdUpd class.
The ProdUpd class is an abstract class, and you cannot make an instance out of it.
You can only inherit this class from other production update classes. To update
production order stage, the following classes are used:
• ProdUpdBOMCalc
• ProdUpdCostEstimation
• ProdUpdScheduling
o ProdUpdScheduling_Operation
o ProdUpdScheduling_Job
• ProdUpdRelease
• ProdUpdStartUp
• ProdUpdReportFinished
• ProdUpdHistoricalCost
• ProdUpdStatusDecrease
o ProdUpdStatusDecrease_CostEstimate
o ProdUpdStatusDecrease_Finished
o ProdUpdStatusDecrease_Release
o ProdUpdStatusDecrease_Schedule
o ProdUpdStatusDecrease_StartUp
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When a production order is updated, there are two main events that can occur.
void run()
{
#OCCRetryCount
RecordViewCache viewCacheProdRoute;
setprefix(ProdMultiStartUp::description());
setprefix(#PreFixField(ProdParmStartUp,ProdId));
try
{
ttsbegin;
this.setParameters();
if (! this.validate())
{
throw Exception::Error;
}
viewCacheProdRoute = null;
viewCacheProdRoute =
ProdRoute::viewCacheProdId(prodTable.ProdId,true);
this.updateProduction();
this.updateBOMConsumption();
prodTable.status().startUpUpdateRouteJobs(this);
this.updateRouteConsumption();
this.startupReferences();
this.updateJobJournal(ParmJobStatus::Executed);
TransactionLog::create(TransactionLogType::ProdStartUp,
strfmt("@SYS76498",
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prodTable.ProdId,
"@SYS77138"));
ttscommit;
this.printout();
}
...
void updateProduction()
{
if (prodParmStartUp.StartUpProduction)
{
prodTable.QtyStUp += prodParmStartUp.StartUpQty;
}
prodTable.ProdStatus =
prodTable.status().isBefore(ProdStatus::StartedUp) ?
ProdStatus::StartedUp : prodTable.ProdStatus;
prodTable.StUpDate = prodParmStartUp.PostDate ?
prodParmStartUp.PostDate : systemdateget();
prodTable.update();
this.addUpdateRec(prodTable);
}
5. The production route is updated and the route journal is created and posted.
(This sample comes from the ProdUpdStartUp.run method reviewed earlier.)
this.startupReferences();
this.updateJobJournal(ParmJobStatus::Executed);
TransactionLog::create(TransactionLogType::ProdStartUp,
strfmt("@SYS76498", prodTable.ProdId, "@SYS77138"));
ttscommit;
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Any references (meaning production orders that are created because of this
production order) are also updated, and the parm table record is updated to show
it is posted.
Scheduling
Scheduling is an iterative activity where the system tries to find a set of resources
that can deliver the product on or before the requested date. In the following
sections, you will review the main production scheduling concepts that provide
an overview of scheduling, resources, the resources data model, and jobs.
Scheduling Overview
The scheduling engine is aligned with the new resource model in Microsoft
Dynamics AX 2012. This introduces capabilities and priorities, and replaces
work centers and work center groups by using resources and resource groups.
You can run scheduling after the production order is created and estimated.
Production dates and other information important to the production process are
established at this point. The role of the scheduling system is to plan the actual
production process so that each operation in the production route is assigned a
starting and ending date and time, and that the materials needed for production
are available when the operation starts.
Another important role of the scheduling system is to assign jobs and operations
to a resource or resource groups. This depends on whether job scheduling or
operation scheduling is used. Running scheduling raises the production status to
Scheduled.
Resources Overview
Microsoft Dynamics AX 2012 introduces resources that are assigned to jobs and
operations. Resources can be different types including machines, tools, human
resources, vendors or locations. The scheduling engine aligns with the new
resource model and can schedule resources based on their capabilities. Resources
and capabilities replace work centers and task groups to provide for more
flexibility in setup and maintenance. In Microsoft Dynamics AX 2012, resources
can be allocated to jobs and operations by matching the capabilities of the
resources with the requirements of the operation.
Alternative resources with the same capabilities are considered, unless there are
requirements for a specific resource or resource group. This applies whether you
select to run job scheduling or operations scheduling. The selection process
consists of matching the requirements of the operation with the capabilities of the
resources. Other requirements, such as location, resource working time, and
resource type are also considered when planning the production. Microsoft
Dynamics AX 2012 has changed the following to the Operations Resource
Model.
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• Separated the way resources are grouped for managing capacity from
the way resource requirements are specified for activities.
• Enabled resources to change resource groups and thereby location
(Site) over time.
• Eliminated the need for defining resources multiple times.
In the following section, you will review resources and recourse capabilities.
Resources
Resources are used throughout the production or project processes. They can be
machines, tools, people, vendors or locations that contribute to the production of
an item. After an operations resource is created, you can assign it to a resource
group and specific productions.
Resource groups have fixed location. You can move resources to another location
by reassigning them to a different resource group. However, a resource can only
be assigned to one resource group at a time. The Effective and Expiration date
fields on the Resource groups tab represent when the resource in question can
be used for production.
With this setup you can share a resource across many sites. When a resource
becomes a member of the resource group that has a different location, it
represents the physical move from one site to another. You can also copy
resources to make the setup of resources easier.
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Resource Capabilities
When designing a route, the requirements that resources must have to perform
the various operations in the route can be expressed as the set of resource
requirements. This allows the allocation of resources to be deferred until
production is scheduled.
You can define capabilities to organize the resources for your operation.
Resource planning and production scheduling depend on correctly defined
capabilities because the requirements of a production are matched with the
capabilities of a resource.
For example, a sheet metal press may have the “Aluminum sheet press”
capability assigned and have a grade of 50, whereas an older sheet metal press
would have the same capability assigned, but the older sheet metal press can only
manage a grade of 30.
EXAMPLE:
On a route, the drilling process time is set to 10 units per hour, but the
requirement itself is defined as “Drilling”.
M1 can drill two units per hour and M2 can drill 11 units per hour.
Both machines can be picked up by the scheduling engine because both satisfy
the requirement: “Drilling”. However, the M1 machine can only drill two units
per hour, far less than the 10 units per hour specified on the route. This will
cause production problems. To resolve this, two separate capabilities should be
created: “Low-speed drilling” and “High speed drilling”. “Low-speed drilling”
is defined by a drilling process time of one to nine units per hour. “High speed
drilling” is defined by a drilling process time of 10 to 19 units per hour.
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In this setup, the M1 machine is given the “Low-speed drilling“ capability and
the M2 machine has the “High-speed drilling” capability. The scheduling engine
will then select the correct machine (M2).
Resource Requirements
When defining the requirements for a production route, you can also specify
skills, courses, certifications or title as requirements in addition to capabilities.
This does not require a relation to a worker. These values are set up in the
Human resource module and are not defined in the Capabilities form. When
defining skills, courses, certifications or title as requirements, you must have the
Human resources module enabled. You can define capabilities in the
Capabilities form that resemble or duplicate those from the Human resources
module. However, the Capabilities form does not contain the functionality that
is required to maintain skills, courses, certifications or titles.
• Skills: You can use the Skills form to create and manage
competencies that are specified for employees or jobs. An operation
can require a human resource with a specific skill, and the
scheduling engine will find resources with the specific skills. It does
this by searching for the skill information on the worker to which the
resource is linked. This is only applicable for job scheduling, and not
operation scheduling.
• Courses: You can create and maintain the courses your employees
have attended. An operation can require a human resource with a
specific course, and the scheduling engine can find resources with
specific courses. It does this by searching for the course information
on the worker to which the resource is linked. This is only applicable
for job scheduling.
• Certificate: You can add certificates to a user in human resources
and use this to track all employee certificates. An operation can
require a human resource with a specific certificate, and the
scheduling engine can find resources with specific certificates. It
does this by searching for the certificate information on the worker to
which the resource is linked. This is only applicable for job
scheduling.
• Title: The title an employee has can also be a requirement for a job.
An operation can require a human resource with a specific title, and
the scheduling engine can find resources with specific titles. It does
this by searching for the title information on the worker to which the
resource is linked. This is only applicable for job scheduling.
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To make sure the system can be easily upgraded from earlier versions, the table
names have not changed. For example, ResourcesTable continues to be called
WrkCtrTable in the physical data model, with the changes in the content of the
table, and in many new relationships.
An example of the new relationship model is the work center resource group,
represented by the WrkCtrResourceGroup table. Now through the association
with the Resource Calendar, WorkCalendarTable (new), and
WrkCtrResourceGroupResource, any resources can have scheduled working
times based on the calendar that is attached to a specific resource. Now the model
can support equipment downtime, swap outs, and upgrades. Additionally, it also
incorporates a more realistic model of human resource management where
workers and other personnel are not available continuously.
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Chapter 10: Use and Design of the Production Control Module
Jobs Overview
Scheduling types differ from one another as measured by detail. Operations
scheduling is limited to scheduling by date (while calculating the duration of the
individual operation), whereas job scheduling calculates the starting and ending
times of individual operations throughout the day. Additionally, there is a
significant difference in the way operations are planned and in how scheduling is
performed in resource groups. Job scheduling splits the different operations into
jobs, and they are planned in detail, for each of the operation resources. When
allocating resources to an operation, the system examines the following resource
requirements types.
• Specific resource
• Specific resource group
• Resource type
• Capability
• Skill
• Course
• Certificate
• Title
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When the requirements are not met by the current inventory, a planned
production order can be issued that specifies what is needed and when. Then the
planner knows what is missing and he or she can make decisions about how to
meet these requirements.
NOTE: Master planning can generate several types of planned orders such as
planned transfer, planned purchases, or kanbans, not just planned production
orders.
The following figure shows the steps for the Master planning module that must
be completed to run and generate the planned production orders.
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Chapter 10: Use and Design of the Production Control Module
LEAN Manufacturing
Lean manufacturing is a both a process philosophy and workable process
methodology. It introduces best practice material handling and best in class
manufacturing methods that are now standard across industries. The core
concepts for lean manufacturing provide a base level understanding of the system
functionality within Microsoft Dynamics AX 2012.
In the following section, you will review the Lean production principles, the
overview and rules for Kanban, and production flow processes.
• Customer Value: When you identify the value, you specify what
creates value from the customer's perspective.
• Identify the Value Stream: The Value Stream is the sequence of
processes that start from the raw material to the final customer or
from the product concept to the market launch. If it is possible, view
the whole supply chain.
• Flow: Create flow wherever possible in the process. Use one piece of
the flow by linking all the activities and processes into the most
efficient combinations to maximize value-added content while
minimizing waste.
• Pull: Make only what is needed by the customer (short term response
to the customer’s rate of demand).
• Perfection: In striving for perfection, Lean is a journey of
continuous improvement. The goal is to economically produce
exactly what the customer wants, and exactly when the customer
wants it. Because perfection is an aspiration, anything and everything
can be improved.
Kanban Overview
In Microsoft Dynamics AX 2012, the Lean manufacturing module introduces
kanbans as a pull-based just-in-time production system. Kanbans relate to a
sequence of kanban jobs. Each kanban job has a status that indicates its current
stage in the production or transfer process. Each kanban also has a status, the so-
called handling unit status that indicates the overall state of a kanban and the
related handling unit.
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• Withdrawal kanbans
• Manufacturing kanbans
• Process jobs
• Transfer jobs
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Chapter 10: Use and Design of the Production Control Module
A Kanban with the type “withdrawal” creates a transfer job that is based on a
single transfer activity. Withdrawal Kanbans are used to move a Kanban of a
specific item between supermarkets, warehouses, and production locations.
Withdrawal Kanbans do not add value.
A fixed quantity Kanban rule relates to a fixed number of bins or Kanban cards.
This means that the number of active Kanbans is constant. When a material
handling unit related to a Kanban is consumed (emptied), a new Kanban of the
same type is recreated. Fixed quantity Kanbans are frequently used with fixed
circulating cards, but can also be used with single use cards. When circulating
cards are used, the card is detached from the consumed Kanban and assigned to
the newly created Kanban.
Scheduled Kanbans
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Event Kanbans
Event Kanbans are only created out of the related demand so that those event
Kanbans belong to the category “make-to-order.” The creation of event Kanbans
is initiated when certain events occur. In Microsoft Dynamics AX 2012, these
events include when you create sales lines, estimate production orders based on
the creation of upper level Kanban demand, or when you reach a certain level of
on hand inventory.
Production Flow
Typically, a Lean manufacturing scenario is more than an accumulation of
unrelated Kanban rules or material supply policies. The flow of material and
products throughout work cells and locations for a specific production or supply
scenario is described as a sequence or small network of process or transfer
activities, which is known as a production flow.
Production flows are the backbone of Lean manufacturing, and they perform the
following functions.
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Chapter 10: Use and Design of the Production Control Module
• Unique name
• Description
• Legal entity that owns the operations in the production flow
• Operating unit of type value stream
• A production group.
NOTE: The production group defines the set of accounts that are used for the
financial postings that are related to the production flow. The most important
accounts are the WIP and Offset accounts. These are the basis of the variance
calculation for the production flow.
The setting of the financial dimension for the production flow is optional.
TIP: For more information about lean manufacturing, refer to the following two
whitepapers.
Additionally, you can refer to the Lean Manufacturing for Microsoft Dynamics
AX 2012 course.
Process Industries
Process Manufacturing for Microsoft Dynamics AX 2012 supports a range of
manufacturing processes. This includes make to order, make to stock, and mixed
mode. Mixed mode is a hybrid environment that enables discrete, lean, and
process requirements to coexist. You can integrate production processes to build
a flexible solution that meets your needs.
Overview
Process industry requirements are reflected in the following Microsoft Dynamics
AX 2012 functionalities.
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Some features can be used with any license of Microsoft Dynamics AX2012,
while other features can be used only with a Process Manufacturing installation.
If your organization wants to use the Process Manufacturing solution, you must
implement one or both of the Process Manufacturing installations.
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Chapter 10: Use and Design of the Production Control Module
Scenario
Victor, the Business Systems Developer, is tasked to add a BOM line item field
to both the BOM and ProdBOM tables. Specifically, the Finance team wants a
new check box called "IsReturnable" to represent if the item or good is
returnable. The objective is to make sure that if the BOM is canceled before the
actual production, the Logistics group is aware they can receive a refund for the
unused goods that are planned for on the BOM, or picked for the ProdBOM.
Challenge Yourself!
Use the following tables, maps, and forms to create a new field for Victor to
track returnable items at the BOM line level.
• BOM table
• ProdBOM table
• ProdBOM form
• BOMConsistOf form
• BOMMap
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Step by Step
4. Save the extended data type. If you are prompted to synchronize the
database, select Yes.
5. Create a project (View > Project or Ctrl+Shift+P ).
6. Right-click the Shared space, New > Project.
7. Name the project.
8. Open the project.
9. Drag the new IsReturnable extended data type to the project.
10. Find the BOM table in the AOT.
11. Drag BOM table to the project.
12. Expand to the Fields node.
13. Find the ProdBOM table in the AOT.
14. Drag the ProdBOM table to the project.
15. Expand the Fields node.
16. Right-click IsReturnable(usr) and select Open New Window.
17. From the new window drag IsReturnable to the BOM fields and the
ProdBOM tables.
18. Close the AOT window with the IsReturn(usr) extended data type.
19. Save the project.
20. In the AOT window, expand the Forms node and locate
BOMConsistOf and ProdBom.
21. Drag the forms to the project.
22. Right-click the project and select Restore.
23. Expand the BOMConsistOf form to Data Sources > BOM > Fields
> IsReturnable, and then right-click and select Open New Window.
24. Expand the BOMConsistOf form to Designs > Design >
[Group:GroupBOM] > [Tab:Tab] > [TabPage:Overview] >
[Grid:GridBOM].
25. Drag IsReturnable to the [Grid:GridBOM].
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31. In the AOT window, open Data Dictionary > Maps > BOMMap
and drag it to the project.
32. Expand BOMMap > Fields.
33. Right-click IsReturnable and select Open New Window.
34. Drag it to the BOMMap fields’ node.
35. Right-click BOMMap and select Restore.
36. Expand BOMMap > Mappings > BOM.
37. Map IsReturnable to IsReturnable in the Properties form.
38. Expand BOMMap > Mappings > ProdBOM.
39. Map IsReturnable to IsReturnable in the Properties form.
40. Save and compile the project.
41. Test and validate the Production order form.
a. In Microsoft Dynamics AX 2012, open Production Control >
Common > Production Orders > All production orders.
b. Click Production order in the New group of the Action Pane.
c. Select item number 11001 HomeTheaterSystem7.1High Perf.
d. Click Create.
e. Double-click the newly created production order.
42. Click the BOM in the Production details group of the Action Pane.
In the BOM form, verify that the Is returnable field is selected for
item number 1101.
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Summary
A bill of material is a complete list of all the components, parts, raw materials,
assemblies and their quantities that are required to make a finished product. The
BOM Version identifies which BOM to use for producing an item under specific
circumstances.
Routes and operations are the path that the item takes from operation to
operation, starting with the beginning of the production process and continuing to
the end. It is a set of sequential operations, or tasks, that are required to produce
an item.
Planned production orders are created by master planning when requirements are
not met by current inventory. A planned production order is issued that specifies
what is needed and when. Then the planner knows what is missing and he or she
can make decisions about how to meet these requirements. This interacts with the
journals for each step for both real time information and auditing purposes.
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Chapter 10: Use and Design of the Production Control Module
1. Which of the following are items that are found on a BOM? (Select all that
apply)
( ) Components
( ) Parts
( ) Assemblies
( ) Raw materials
4. Which of the follow is true about Production Orders? Select all that apply.
( ) Meeting sales demand when inventory is insufficient
( ) Creating safety stock based on possible demand
( ) Developing templates for receiving control
( ) Supply the BOM as sub-assemblies to other items in demand
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1.
2.
3.
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Chapter 10: Use and Design of the Production Control Module
Solutions
Test Your Knowledge
1. Which of the following are items that are found on a BOM? (Select all that
apply)
(√) Components
(√) Parts
(√) Assemblies
(√) Raw materials
4. Which of the follow is true about Production Orders? Select all that apply.
(√) Meeting sales demand when inventory is insufficient
(√) Creating safety stock based on possible demand
( ) Developing templates for receiving control
(√) Supply the BOM as sub-assemblies to other items in demand
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