Shop Floor System

The Shop Floor Control system integrates with other JD Edwards World systems to take advantage of
single entries, information sharing, and data consistency across systems.

Figure 1-1 Shop Floor Control System

Description of "Figure 1-1 Shop Floor Control System"

 The Product Data Management system provides information about bills of material, work centers,
and routings.
 The Inventory Management system allows you to track materials between inventory or storage
locations and the shop floor. You can perform inventory issues, commitments, and completions,
and track order quantities throughout the production process.
 The Sales Order Management system allows you to generate work orders when you enter a sales
order and updates sales information from within the Shop Floor Control system.
 The Capacity Requirements Planning system reads the routings for work orders and rate schedules
and monitors the load on the work centers involved. This allows you to effectively manage the
loads on your work centers to maximize production and meet scheduled demand.
 The Payroll system interface allows single entry of employees' hours. You can record hours and
quantities per work request or per employee to accommodate both piece-rate and hourly rate
employees.
 The Procurement system allows you to automatically generate purchase orders for subcontracted
operations on your routings.
 The Distribution Requirements Planning, Master Production Scheduling, and Material
Requirements Planning systems provide suggested purchase and manufacturing orders required to
maintain a valid production schedule.
 The Warehouse Management system allows you to originate picking requests through
Manufacturing systems, which further enhances the automated method of tracking inventory
movement within a warehouse.
1.2 Features
The following graphic illustrates the features available to you in the Shop Floor Control system. These
features are described in detail following this graphic.

Figure 1-2 Shop Floor Control System Features

Description of "Figure 1-2 Shop Floor Control System Features"

Hours and Quantities Tracking

 Enter and track time and quantities completed and scrapped by work order and by employee
 Allocate and track resource usage by work center per calendar month
 Review and analyze reports of work orders with detail by operation of standard versus actual for:
 Setup, labor, and machine time
 Quantity complete and scrapped
 Charge actual hours and quantities to a work order as each manufacturing step is completed

Process or Routing Instructions

 Generate a routing automatically when a work order is processed

 Use master routings or non-standard routings for items and indicate when to use each item
 Change the work centers and procedures for each operation on the routing
 Modify the sequence and status of each operation on the routing
 Make real-time modifications to routing instructions
 Display quantity ordered, completed, and scrapped for each operation

Work Order and Rate Creation

 Enter work orders and rates manually

  Create work orders and rates automatically from Material Requirements Planning (MRP) by
answering action messages, or from sales order entry and select kits for assemble-to-order
environments
 Generate shop floor paperwork automatically, including standard parts lists and routing
instructions
 Differentiate work orders and rates by type, priority, and status
 Group work orders by a parent number (a useful feature for job numbers that contain many work
order numbers)
 Automatically generate purchase orders for sub-contracted operations on the routing for work
orders and rates

Blending, Filling, and Packaging

 Produce and track work orders for the filling and packaging of lube oil finished goods when:
 Blending products requires more than one co- or by-product
 Blending and filling on the same work order
 A flushing step is required that produces a by-product
 Using Super Backflush to complete products in separate steps

Production Scheduling and Tracking

 Schedule work center production for rate schedules, work orders, or both
 Track and compare planned production schedules against actual schedules
 Use the online scheduling workbench to review, dispatch, and update production scheduling
information in real-time
 Calculate start and complete dates for each work order by operation from the Shop Floor Control
Routing Instructions table (F3112)
 Maintain the rate schedule after using rate based MRP

Manufacturing Accounting

 Plan and track costs for setup, labor, material, and overhead
 Compare planned costs against actual costs and calculate a variance amount
 Use feature cost percent for co-/by-product costing
 Create journal entries to charge actual and variance costs to a work order or rate schedule in the
general ledger

Material Tracking

 Create a parts list automatically when you process a work order

 Display the quantity on order, on hand, and available for each part
 Access detailed information about supply and demand quantities
 Check the availability of the components required to manufacture a parent item and generate a
shortage list
 Issue the parts to a work order using a manual, preflush, or backflush method
 Backflush both quantities of components issued to a work order and the labor expended with pay
point operations
 Enter and track completions to inventory when parent items are completed
 Attach the parts list and routing instructions to the work order and print shop floor paperwork
 Track where lots are used, and split and trace where lots come from with advanced lot control
 Maintain and monitor work orders created from the Configuration Management system for
configured items
 Process work orders that produce co-products or by-products and process the necessary
transactions
 Generate an inventory shortage list by work order and item
  Enter issue transactions for inventory items associated with a work order
 Generate a picking request in the Warehouse Management system to select a location and move
the inventory (this occurs after the Manufacturing system creates a parts list without a work center
attached, and checks availability)

Reporting

 Run reports that compare actual values with planned values and indicate the variance between the
two
 Run shortage reports by item or work order to identify potential manufacturing constraints due to
a lack of availability of required components
 Print shop floor paperwork, such as work orders, parts lists, and routings for items
 Review daily shop work lists to monitor job status, identify queue problems at work centers, and
flag other areas, such as engineering changes or lost material

1.3 Process Flow

The following graphic illustrates all of the processes involved in the Shop Floor Control system. The
arrows show the flow from process to process, beginning with a work order and ending with an inventory
completion.

Figure 1-3 Shop Floor Control System Processes

Description of "Figure 1-3 Shop Floor Control System Processes"

LABOR ENTRY
Menu option -1344
This is option 1344 is used to report Labor transactions into Harris Data Collection System (HDS) and
collect Batch Lot (B/L) information for non-Finished Goods (FG) items.
Definitions
LPAR – Logical partition on AS400 representing the environment.
Mapics / Infor XA - Manufacturing, Accounting and Production Information Control Systems
- software package
MO – Manufacturing order
OPSEQ – Operations sequence number for order
Warehouse – MAPICS identifier for a facility within a Site ID.
P&IC – Purchasing and Inventory Control department
MFG – Manufacturing
Badge – Employees badge number
Plant Number - is default of user sign-on
Batch/Lot# - information collected for carb regulatory information from vendor
Completed Pieces – number of pieces completed
Scrap Pieces/code – scrap quantity and scrap reason code
Pieces to rework/code – quantity to rework and reason code
Labor Code – labor for the reason code
Operation Complete - “ “ or “Y” (if the order has been completed then enter a “Y” in the
field.)
T&A – Time & Attendance system
HDS – Harris Data System
DCS – Data Collection System
FG – Finish Goods
P&IC - Purchasing & Inventory Control
Query to find active employees
WITH empmaxeffdat
AS (SELECT emempl AS EMPLOYEENUM,
Cast (Max(emeffdt) AS DATE) AS MAXEFFDAT
FROM emmstr GROUP BY emempl)
SELECT emempl,
emcomp,
emfacl,
emplnt,
eterdt,
empbdge,
mpacrec
FROM emmstr
JOIN empmaxeffdat
ON ( emempl, emeffdt ) = ( employeenum, maxeffdat )
WHERE eterdt = '0001-01-01'
AND mpacrec = 'A'
ORDER BY emempl

Data Collection Code

10 Shift On
15 Shift Off
20 Setup Time On
25 Setup Time Off
30 Run Time On
35 Run Time Off
40 Rework Time On
45 Rework Time Off
50 Indirect/Downtime On
55 Indirect/Downtime Off
60 Add To Active Group
65 Remove From Group
70 Combine Groups
75 Change Group

What is an employee Badge number?