405 CD Labor Reporting

[MacWheel99@xxxxxxx]

I posted this when the midrange.com ISP was apparently down & got no response 
so I reposting it just in case Y"all did not see it ... I am now assured the 
ISP is back up again.

From:   MacWheel99@aol.com (Al Macintyre)

We are 405 CD AS/400 V4R3 mixed mode.

Vanilla BPCS recognizes that a shop order has been completed when quantity 
completed consumes standard hours needed, and or all operations completed by 
labor, irrespective of quantity.  Inventory status, such as consumption of 
raw materials is irrelevant to this determination.  But accuracy in inventory 
is critical to us, so we use JIT600 to keep material consumption & labor 
reporting in sync & avoid premature order closings with this data not in sync.

In the past we have not bothered with reporting anything other than human & 
machine time, but in an effort to reconcile time expended by production 
workers with payroll time, we have lumped their other time with the 
"production time" on closest part actually worked on.  This has distorted our 
true costs (e.g overtime) and actual rates, so we now wish to track 
non-production time separately.

We do not use, nor at this time desire to use: lot control; containerization; 
CIM bar coding; Quality Assurance through BPCS.

Our ideal scenario is:
Inventory accuracy continuous improvement;
nail down production rates & costs;
start tracking setup time;
other time totaled by reasons;
total time resemble payroll hours.

Is this an achievable set of goals?

A co-worker tested setup & downtime & tracked what happened to their costs, 
talking about changes we need in work centers.  He could not figure out how 
to get JIT600 to accept them (I do not yet know what his error message was) & 
I am digging into program & documentation to try to figure out why, but 
SFC600 was no problem.

Is it reasonable for me to expect that hours reported will not accumulate 
against total time, irrespective of labor transaction type used, and if 
user-A on session-A for JIT600 session for quantities & machine & labor hours
while session-B for setup & downtime & indirect via SFC600, 
that the SFC600 batch ought to be concluded before the JIT600 batch in case 
the latter activity is completing orders found in the former?

My users unhappy with this analysis because same labor ticket might have both 
production time & other time & there is a desire at JIT610 transcription 
audit time to look at a bigger picture ... I mumbled something about possibly 
linking open sessions belonging to same user (if that is practical), that are 
not currently in middle of JIT600 for consolidated edit.

Are there any labor time transaction types that do not have to be against a 
particular shop order or item ... I am digging into the vanilla documentation 
& portions of it not organized well for figuring this out.

Al Macintyre  ©¿©
MIS Manager Green Screen Programmer & Computer Janitor of BPCS 405 CD Rel-02 
running on AS/400 V4R3
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