RE: Kan Ban

[klvanhorn@xxxxxxxxxx]

Joe does an excellent job of explaining JIT below.  He mentions "Faking"
production reporting. 

We did just that on 6.0.04 HP/Oracle.  For areas with multiple subassemblies
and short manufacturing thru-put times.  We created a flat BOM  and a long
detail route with all the operations listed under the (grand) parent as
non-collectable, and a dummy final operation used to report production as
collectable.  Each of the sub assemblies was listed on the as a component to
the parent and was changed to a phantom item type.  (Raw material did not
need to change, just components.)   As Joe mentions below, you cannot track
actual labor or issue materials to these subassemblies. 

This allows you to create a shop order for the parent and still have
workcenter schedules with the detail of each operation.  It will backflush
the labor at standard to the correct workcenter and all raw materials at
standard.  We don't use this if we need visibility to any of the components
for any reason. 

 At physical inventory time we had to do a little extra work, since we
didn't have applied costs for these phantoms.  But you can work around that
if you tell the accountants ahead of time.

That's not using the system as designed, but it works for what we needed.  I
don't know if the same functionality exists in 4.05CD.

If you have questions, you can contact me for further details.

Kent Van Horn
lkvanhorn@huntel.net
(402) 533-2312

        ----------
        From:  Pluta@nexgensoftware.com[SMTP:Pluta@nexgensoftware.com]
        Sent:  Tuesday, June 06, 2000 3:49 PM
        To:  BPCS-L@midrange.com
        Subject:  Re: Kan Ban


        Unless I'm mistaken, your scenario requires more than I designed
when I
        originally wrote the backflushing code for BPCS oh so many years
ago.  The
        first cut of JIT backflushed only material, and then when the
fullscreen
        version of JIT600 was introduced, we added backflushing of labor.
Your
        particular case requires not only the backflushing of labor and
material,
        but also the backflushing of PRODUCTION - specifically, backflushing
the
        production of the subassemblies.

        You see, JIT is only designed to post the standard hours and consume
the
        standard quantities for the labor and materials of the current item.
It
        assumes that the materials are already in inventory, which for
        subassemblies would mean that you had already posted the labor and
        inventory transactions for those subassembly items.  You could use
JIT to
        backflush those hours and materials, but you still have to post
production
        for each of the subassemblies.

        What you'd like to have happen is that whenever a subassembly is
consumed,
        that BPCS would automagically backflush the labor and materials for
the
        subassembly as if you had posted production of the subassemblies
that were
        just consumed.  While not impossible, this would require quite a bit
of
        razzle-dazzle on the part of BPCS, and would in fact require an
additional
        switch somewhere to allow you to choose between "through-posting" of
        subassemblies and the default of simply relieving inventory.  In the
case
        of "through-posting", the best bet would be to create a new JIT
production
        order (basically a shop order) for the subassembly and somehow
"fake" a
        posting of production to it.

        The final kicker is that there's no good way to tie the shop orders
        together, since each shop order only produces a single item, so the
end
        item costs would not reflect the "through-posted" labor and
materials.

        Of course, I've been away from the guts of BPCS for a good handful
of
        years, so take this with a grain of salt.  Anybody else care to
comment?

        Joe Pluta
        www.java400.net
        www.plutabrothers.com



        

                            David_Baxter@si

                            emon.com               To:
bpcs-l@midrange.com                                               
                            Sent by:               cc:

                            owner-bpcs-l@mi        Subject:     Kan Ban

                            drange.com

        

        

                            06/06/00 01:38

                            PM

                            Please respond

                            to BPCS-L

        

        





        Currently using 405cd and looking for anyone using BPCS to support
Kan Bans
        or
        reduced labor / production reporting. Ideally we want to eliminate
the
        cutting
        of shop orders, backflushing and labor reporting at the sub-assm
level and
        only
        cut shop orders and report production at the finished goods level.
To
        accomplish
        this we need a way of attaching the sub-components to there grand
parents
        BOMs
        so when we report the finished goods production we consume the lower
level
        components. If we simply add the components to the grand parent BOM
we
        would
        need to re-do all work instructions and drawings. Additionaly, we
would
        end-up
        with a finished goods BOM that is not accurate due to it showing the
lowest
        level components and not the sub-assm actualy used in production.
        Any suggestions or experience would be appreciated.


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