RE: Multiple-level Bills of Material -- BPCS-L

Al Mac - you sound as you're in the same situation we're in.  While the
production code hasn't been modified as much as yours (sounds like) it IS
getting pretty tailored.  Our problem is that while 70% of our sales come
from that item that is one component/one finished good, others are multiple
components at multiple levels with internal semi-finished items and outside
operations.  Oh - what we make are cutting tools for other manufacturers.
So the large portion of sales is the indexable inserts while the supporting
items are the toolholders, milling cutters, etc.

Looking at the shop orders, I don't there'll be too much heartburn modifying
them to print all levels of components.  Maybe, as you've done, it could
even be done with a query.

Thanks, guys and gals.-

-----Original Message-----
From: bpcs-l-admin@midrange.com [mailto:bpcs-l-admin@midrange.com]On
Behalf Of Al Mac
Sent: Wednesday, December 18, 2002 3:02 AM
To: bpcs-l@midrange.com
Subject: Re: Multiple-level Bills of Material


--
[ Picked text/plain from multipart/alternative ]
405 CD user

Have you visited my personal web site directory of BPCS documentation
providers
http://radio.weblogs.com/0107846/stories/2002/11/08/bpcsDocSources.html
scrolled down to very bottom and taken a look at OTTO?
BPCS MRP/MPS uses BOM lead times
BPCS SFC/CAP uses routing times
OTTO uses current orders to identify which SFC/PUR orders WIP and inventory
do not support customer demand

Your parts sound much simpler than ours, so maybe you can do stuff we can't

I doubt you can get what your boss wants without modifications, but you can
get at some approximations without serious modification.  We have been
rather creative with queries/400.

FMA is to shop order material requirements what MBM is to Bill of Materials.

If you can concoct a query/400 report off of this that satisfies your boss,
perhaps the data need not been in the shop order per se, just something
that is printed with the shop packet.

We have one query which matches the CHILD item of FMA with the PARENT item
of FSO to show how we doing on getting ready with the materials that go
into the shop orders for the PARENT items of the FMA involved.

We have several queries that create query work files (I keep most of our
query work files, and 400 *OUTFILEs, in a library called XFILES because we
doing some really strange things with them) that are then input to other
queries.

Perhaps we should send you a sample of one of our shop order labor tickets,
or let you pick up a sample when you visit.  Perhaps we should also give
you a screen print from JIT600 since we added a bunch of fields that
Vanilla BPCS not have, and we blanked out those we not populate.  Otherwise
some of the stuff on our labor tickets might seem a bit strange.

Our labor ticket has a bunch of boxes for people to fill in how many made,
by whom (team), time, etc.
There is a mid-column printing instructions how to make the part, off of
FOD additional instructions.
Over at far right is BOM Where/Used info
The BOM lists the components that go into this step
The Where Used lists end items that this production might be FOR (we use a
lot of common sub-assemblies)
If the operation is to DO something with a particular part, that part #  is
identified on the ticket.

This is as a result of HEAVY modifications piled on more and more
modifications.
When SSA came out with BMRs (we no longer trying to stay current) and I
need to merge what they done with what I done, the shop ticket printing
program has in the neighborhood of 2,000 lines of code (code, not counting
comments) that we added that aint in vanilla.  We using SQL very heavily in
this program.

Our modifications were because
    * the people doing setup needed to know what materials to stage for
production of an operation,
    * the people supervising an operation that uses MANY sub-assemblies ...
such as assembly of MANY wires ... they wanted to be able to track down all
the incoming components
    * when an operation gets completed, they wanted visibility of where
that part goes to link up with other parts
I also created a program BOMRATE
You key in item # and facility.
It goes down the complete BOM on that item.
For each item that is manufactured,
it shows the routings data = standard rates
it shows the labor history = actual rates
it identifies any shop orders currently open & what rates we getting on
them so far
This started out as a simple program and I kept adding to it.

Its purpose in life is ... we have these complex parts, with like 100
separate wires, combined in many steps ... some finished parts have wild
cost variances ... so we run this for the end item, and pretty fast we can
see which sub-assembly is responsible for the deviation.

I have suggested to my boss on more than one occasion:
We have done many modifications to 405 CD - some of them with the help of
various consultants.
For those that did not have help from consultants, the only copyright in
there is SSA and us
In theory, if we were to supply copies of that source code to some other
company that uses 405 CD, so long as THEY have an SSA license, we not doing
anything unethical.
If the OTHER company finds value in our work, which they would get AS IS,
with no promises of support from us, it could save them a lot of time and
effort duplicating our work, and they might be willing to pay us some $$$$$
to be negotiated ... does it work for them, what do they think it is worth.
The same notion in our direction ... stuff we might have wanted to do, but
too much trouble to pursue, or more money to buy from a consultant than we
want to pay ... if we can get source code from other companies on 405 CD
where they done modifications, and get that uploaded to the 400
My boss has not seemed to be receptive to pursuing this ... I suspect he
just too busy.

Al Macintyre
BPCS/400 Computer Janitor at http://www.globalwiretechnologies.com/
See Al http://www.ryze.com/view.php?who=Al9Mac
Find BPCS Documentation Suppliers
http://radio.weblogs.com/0107846/stories/2002/11/08/bpcsDocSources.html

>4.05CD (the only way to fly)
>
>Our boss wants to see the complete bill of material on shop orders.  Is
this
>do-able without program modifications?  Our product line is generally
>buy-one-modify-one-sell-one, but in a few areas, we buy one, make something
>and stock it, then make something else out of it.  I can modify SFC560 to
do
>this, but he'd also like to see it on MRP reports, at least the exception
>and detail reports (MRP200 and -240).  So I guess this is a two-pronged
>question:
>
>Without programming, can:
>
>SFC560 print a multiple-level bill of materials
>
>MRP200 and 240 print something approaching that, along with the associated
>orders?
>
>Thanks - Rob
>
>-----Original Message-----
>From: James Barry
>Subject: Re: MPS - Customer Demand and General ECL Date Questions
>
>
>BPCS 4.05 CD..
>Detail Capacity Planning job runs 2 pgms:
>1. Read Detail FOD records from Open Shop Orders
>     ( which were created from std Boms, Rtgs, Wrk Ctrs....
>       and which may have been manually manipulated)
>2. Read Planned Orders (KFP) from MRP/MPS,
>     then read std Boms, Rtgs,Wrk Ctrs, Shop Calendar
>     (similarly to SFC500 )
>
>THUS
>MRP/MPS Uses a lead time entry
>SFC/CAP uses rtgs hours & qtys *& available days....
>
>Jim Barry
>..........................
>
>
>On Thu, 12 Dec 2002 10:29:31 -0500
>   DeeDee Virgei <DeeDee.Virgei@nelsonstud.com> wrote:
> >Say Hi to Al for us...
> >
> >-----Original Message-----
> >From: Rob Stagis
> >--
> >Also on 4.05CD and planning on visiting Al Mac, though he
> >doesn't know it yet :)

Al Macintyre
BPCS/400 Computer Janitor at http://www.globalwiretechnologies.com/
See Al http://www.ryze.com/view.php?who=Al9Mac
Find BPCS Documentation Suppliers
http://radio.weblogs.com/0107846/stories/2002/11/08/bpcsDocSources.html
--

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