RO-A Enter Routings
Purpose of Program
Use this program to define how and where a finished good or assembly is manufactured. Each finished good or assembly is broken down into specific sequences (operations), which can be for direct labor or for outside processing. The information in the routing file will be copied to the work order routing file when a work order is firmed in the Work Orders module. From there the information will print on the shop traveler. Routings can be used for costing purposes, or if work centers are defined with $0 labor and overhead rates, the Routing can be used as a written work instruction (as for ISO 9000 certification) and for scheduling and capacity planning while labor costs are captured via a type L part number.
The inventory item number for the finished good or assembly to be manufactured. This must be a valid item in the inventory file, and should be inventory type F (finished good) or A (subassembly).
The inventory description for the finished good or assembly to be manufactured. This field displays automatically and cannot be edited.
The typical lot size (quantity) per production run. This is used to convert setup cost, which is a flat dollar amount regardless of quantity, and vendor minimum charges for outside processing into a per unit cost for standard costing purposes. Obviously production quantities will vary, so enter an average or best guess.
The routing sequence number. This is a three character numeric field. Many users number their sequences 10, 20, 30 etc., so there is room to insert sequences, if needed. Sequences will print in numeric order on the shop traveler.
The operation number of the labor process or outside processing being performed at this sequence. If you are using templates through RO-I Enter Operation Templates, the template number can be the operation number. An operation can occur more than once within a routing. Forming, for example, could occur in several sequences. If you are not using operation templates or standard operation numbering, the sequence and the operation can be numbered the same.
The operation type. Three types are available: L for direct labor, P for outside processing, and A for alternate operation. The default value is L for direct labor, which is for any in-house operation.
An alternate operation is one that is not standard, but could be used as an alternative. For example, you might normally paint an item in house, but if the plant were busy, you could send the part out for painting. Outside painting would be an alternate operation. The Print/Rollup Routings Costs program bypasses alternate operations in its cost calculations.
Outside processing is any service that is performed by a vendor, such as plating, painting, galvanizing, etc.
A short, 30 character description of the operation to be performed. This is the description shown on the shop traveler and various reports.
Enter R if this sequence will always be Run Time (never Setup), S if it will always be Setup and leave blank if either Run or Setup Time may be reported against it.
The work center this operation is to be performed in.
The routing number for shop traveler printing purposes. The default value is 1. If you wish to have multiple shop travelers on one work order, you may specify which routing this sequence is to print on. When shop travelers are printed, each routing will print on a separate traveler, with common header information on all travelers. For example, a manufacturer could break an assembly into three processes and manufacture each process separately. Using routing numbers would allow three separate travelers to be printed for the same work order, each with a unique set of sequences. Apart from the printed traveler, however, there is still only one actual routing.
Time Type & Lines/Comp
Access to this setting is controlled by DEF-I Routings Defaults (Evo-ERP) setting for "Enable Template Time Types" and is intended to be used in conjunction with Routing Templates entered at RO-I Enter Operation Templates. Leave blank or enter F if this sequence is a flat time per part Run time plus possible Setup time. Enter "L" if this sequence time is determined by the number of Line Items on the BOM and independent of the Work Order quantity (such as a sequence to kit the job in the stockroom) and then enter the number of Line Items in the Lines/Comp field. Based on the multiplier that was entered in the template, the program will calculate the total time and save it as Setup time. Enter "C" if the sequence time is a function of the number of components being processed (such as a soldering operation) and enter the number of components in the Lines/Comp field and the program will multiply by the factor entered in the template and save the result as Run time.
The number of processes that occur within this operation. For example, this operation may require three separate bends, which would be three processes. Or, the process might could involve a mold that holds nine cavities, which would be nine processes. The default is a value of one. If you enter any value other than one, the next three fields appear in a pop-up window.
How much time each process takes, in decimal hours. 3 minutes would be entered as .0500 hours. You can skip this field and enter the next field, Processes/Hr, which will calculate a value in this field automatically.
If you enter a time/process in the previous field, this field will automatically be calculated. If you skip the time/process field, enter the processes per hour to establish a standard production rate for this operation.
Multiply or Divide by #Processes [M,D]
If, in the first example where there are three bends to the process, you want the processes/hour to be divided by the number of processes in order to calculate the finished parts/hour and time/part. Enter a D in the field. If each bend took 30 seconds, the production rate would be 120 bends/hour. Divide 120 bends by three processes and you will get 40 finished parts per hour for this operation.
In the second example where you have a nine cavity mold, you might get 10 shots produced per hour. In this case you want to multiply the number of processes, so enter an M. 10 shots per hour, multiplied by nine processes will give you 90 finished parts per hour for this operation.
The time required to manufacture each piece. Normally time is entered in hours, minutes, and seconds. If you prefer entering decimal time, or if the number of hours per part is ever to exceed 99 hours or you need greater precision per part than one second, you can have an optional decimal field display in a pop-up window that will allow entry of up to 9,999 hours and seven decimal places. This decimal field is referred to as the Long Time field, and it can be made to appear by setting the Display Long Time Prompt? field to Y in SD-I Routings Defaults. If this field is skipped and the next field, Parts/Hr, is entered, this field value will be calculated automatically. If production rates were entered against processes in the processes window, this field value will be calculated automatically.
The number of finished parts per hour expected for this operation. If the previous field, Time/Pt, is entered, this field value will be calculated automatically. If production rates were entered against processes in the processes window, this field value will be calculated automatically. If you change the Time/Pt, the Long Time field or the Parts/Hr field, the other fields will also be recalculated.
The time required to set up this operation. Setup time is entered in hours, minutes, and seconds.
Overlap - Forward
SH-E Finite Scheduling currently supports the use of Forward Overlap. Forward Overlap is entered in hours. If you enter Forward Overlap in a routing sequence, it means that after the sequence is completed, the parts will not move on to the next sequence until after the number of Forward Overlap hours has expired. A typical use of Forward Overlap would be to let paint dry before the parts can move on to another operation.
Overlap - Backward
SH-E Finite Scheduling currently supports the use of Backward Overlap. Backward Overlap is entered in units of parts. If you enter Backward Overlap in a routing sequence, it means that once the number of Backward Overlap parts has been produced in the current sequence, the next sequence can begin using the parts already produced, even though the current sequence is not yet completed.
Some operations by their nature are impossible to track time to. For example, a polishing process might involve one person simultaneously running 20 work orders on automatic machines. It is not practical to allocate actual time to so many work orders. For such operations, you can set this field value to Y. When finished parts are reported through WO-F Enter Labor or DC-B Enter Production Only, or WO-M Batch Labor Entry the program will automatically apply the standard time/part for this routing sequence.
The number of persons it takes to perform this sequence. This field allows two decimals, meaning you can have half a person, if necessary, such as when one person runs two work orders on two separate machines simultaneously. The Print/Rollup Routings Costs program will multiply the standard work center labor rate by this value to calculate the standard labor cost for this sequence.
The specific machine, if applicable, this sequence runs on. Must be a valid machine in the machine file. The machine description is automatically displayed.
The specific tool, die, mold, fixture, etc. required for this operation. Must be a valid item in the tool file. The tool description is automatically displayed.
If this is an outside processing operation, this field is the vendor code for the vendor which normally performs this operation. This must be a valid vendor in the vendor file. If you don't know the vendor until time of purchase order, leave blank or set up a dummy vendor that is recognizable as meaning "no specific vendor."
The standard per unit cost for the outside processing on this operation. This will be used by the standard costing system in inventory. If the work center for this outside process has a Cost/lb default, the routing program will multiply the item's weight by that cost and will insert the result in the Cost field where it can be overridden if desired.
The minimum charge, if any, for an outside process. The Print/Rollup Standard Costs program will use the result of the (lot size x cost) or the minimum charge, whichever is greater. Within the Estimating program the calculation for each estimate quantity will use the result of the (quantity x cost) or the minimum charge, whichever is greater. If the work center for this outside process has a Minimum default, it will automatically enter into this field where it can be overridden if desired.
Lead time for this outside processing operation. The number of days normally required between sending out items for outside processing and receiving them back. This value will copy in automatically from the lead time field in the work center specified for this operation and is used by the Scheduling programs to allot time for the outside processing.
Up to 15 lines of free form text may be entered to define how this sequence or operation is to be performed. These Notes print on the Shop Traveler and for Outside Processing sequences can also pass to the Purchase Order to the vendor for the processing.
Specs are similar to notes, except they have predetermined fields and headings. They allow you to customize your routings with specifications unique to your industry. For example, specs can be used to hold die settings, temperatures, inspection fields, etc.
NOTE: If you want the columns in specs to print aligned on the graphical traveler, you need to change the font of that section of the traveler RTM to a non-proportional font such as Courier New using Modify Forms
General Program Operation
Enter the item number of the finished good or subassembly to be manufactured or select a item number from a pop-up window by clicking on the Lookup icon (or press F2). The inventory description will automatically be displayed. You may next enter a lot size in the Lot field, which represents the most typical production run quantity for this item. The setup time is divided by the lot size to translate setup into a unit cost for standard costing purposes.
If no routing exists for this item, you will be prompted with a message ? Routing has not yet been set up for this part. Would you like to use the Routing Generator to quickly accomplish this?? If you reply ?? a list of templates that have been entered in RO-I Enter Operation Templates will be displayed from which you can select in order the ones that apply. Once all the templates have been selected, click on the Save button (or press F10) and a complete routing will be generated, automatically sequenced in the order that the templates were selected. The sequence numbering increment (1,2, 3, etc., or 10, 20, 30, etc.) can be preset by you through SD-I Routings Defaults.
If you reply ?? you will be able to manually enter the Routing sequences. The cursor is now located in the entry area at the bottom of the screen. Enter a sequence number or copy in templates as explained in the next section. Many users number their sequences 10, 20, 30 etc. to leave room for inserting extra sequences, if necessary.
If you enter past the Seq field to the Op field you can click on the Operation Templates button (or press F2) to display operation templates for standard operations as defined in RO-I Enter Operation Templates to select them individually.
Once operation templates are copied in you can bring those routing lines into the entry area and edit any of their fields.
If you are not using operation templates, you must enter an operation number. This can be the same number as the sequence number if you have no reason to differentiate between the two.
The routing type selections will automatically display in a window. The default is for type L, for direct labor. If the operation is performed in house, it is an L type operation. If the operation is for outside processing, such as painting, plating, galvanizing, etc., it is a P type operation.
If you wish to define a secondary or alternate way to perform the same operation, you may select type A for alternate operation. For example, you might normally paint an item in house, but if the plant is busy, you could send it out for painting. Outside painting would be set up as an alternate operation. The Print/Rollup Routings Costs program bypasses alternate operations in its cost calculations so that the same basic operation is not costed twice. Alternate operations will copy into the work order routing file when work orders are firmed. If you do not want them printed on the shop traveler, you will have to go into the work order routing file and delete alternate operations.
You may next type in a brief 30 character description of the operation to be performed. This is the description used on reports. If you copied in an operation template, this field would contain the standard short description for this operation.
Next, specify the work center this operation is to be performed in. You may type in the work center code or you may select a work center by clicking on the Lookup button (or press F2). The work center description will automatically be displayed. All sequences must be performed in valid work centers, including outside processing.
If you specified this operation as outside processing, the cursor will advance to the vendor field. If you specified this operation as direct labor, the cursor will move to the #Proc field.
Outside Processing Sequences
When entering the vendor code in the Vend field you can type the code directly or you can select a vendor by clicking on the Lookup button (or press F2). The vendor name will automatically be displayed. If this is an operation where no specific vendor is known in advance, you can set up generic vendors in the vendor file, such as "Plating Vendor" or "Painting Vendor." These will appear on the shop traveler and on purchase requisitions and will immediately signal to the purchasing department that a specific vendor must be selected at purchasing time.
The lead time will copy in automatically from the Lead Time field in the work center specified for this operation. This only pertains to outside processing operations. The lead time represents the average number of days between issuing the items for outside processing and receiving them back. The default lead time may be overridden.
Enter the standard unit cost for the outside processing to be performed. This is the standard cost which will be incorporated in the Print/Rollup Routings Costs program and the inventory standard costing system. If there is a minimum charge, enter it in the next field. Defaults for the Cost and Min Charge fields can be set up in the work center for this outside process through RO-C, Enter Work Centers.
If this is an outside processing operation, you will not be allowed to enter any of the remaining fields on screen one. If you click "Notes" or press <Page Dn> you may enter free form notes describing how this operation is to be performed which will pass through to the Purchase Order for the processing. Click "Specs" for specifications (also accessed by pressing the <Home> key). You may enter notes and continue pressing <Enter> until the system asks you if you want to save the record, or you may save the record at any point by clicking on the Save button (or press F10).
Direct Labor Sequences
If you are entering a direct labor operation, the cursor starts at the #Proc field after the Rout# has been entered.
If more than one process occurs within a sequence, such as multiple bends, or multiple cavities, enter the number of processes. If any value is entered other than one, a pop-up window will allow you to enter the time/process, the processes/hour, and whether you want to divide or multiply by the number of processes. See Field Explanations above for details on how to enter these fields.
If you accepted the default of 1 in the #Proc field, you can enter either the time/part or press <Enter> to skip this field and enter the parts/hour to establish a standard production rate for this sequence. Either field automatically calculates the other. Time per part is normally entered in hours, minutes, and seconds, but it can be entered in decimal hours if the Display Long Time Prompt? field is set to Y in SD-I Routings Defaults. These times will become the standard rates that will determine the labor and overhead costs for this sequence, and they will be the rates with which employee performance will be compared. The system will accept values of zero if you are setting up "dummy" operations or have not yet established time standards.
Enter any setup time required for this operation in the Setup field. Setup time is entered in hours, minutes, and seconds. When the Print/Rollup Routings Costs program is run, the total setup cost is divided by the lot size entered at the top of the screen to calculate a per unit standard setup cost for this sequence. If you are using setup time, make sure you have entered a lot size. A lot size of zero is treated by the cost rollup as a lot size of 1 so every piece will be charged the full setup time if no lot size is established.
If this sequence does not lend itself to labor tracking, you can enter a Y in the Std Time? field and WO-F Enter Labor will apply standard time to any reported production. See Field Explanations above for more details on this field.
If you want multiple shop travelers, you can assign this sequence to the appropriate routing number. The default is ?.? See Field Explanations above for more details on the use of multiple routing numbers.
Enter a machine number in the Mach field if this operation must run on a particular machine. You may type in the machine number or select a machine by clicking on the Lookup button (or press F2). This field may be left blank.
Enter a tool number in the Tool field for any tool, die, mold etc. used by this operation. You may type in the tool number or select a tool by clicking on the Lookup button (or press F2). This field may be left blank.
You can access the Notes screen from any field by pressing <PgDn> (or by clicking on the Notes button).
Enter any notes and then keep pressing enter until the system asks you if you want to save the record, or click on the Save button (or press F10) from any point within screen one or screen two when you are ready to save the record.
After saving a sequence, the entry area is cleared for entry of the next sequence. Continue entering sequences as needed. To exit the screen, press <Esc> (or click on the Exit button).
To edit existing sequences, you must move them into the entry area. While in the Seq field you can click on the Display Lines button (or press F2) to get a listing of existing sequences in a display window. Highlight the sequence you want and press <Enter> or click on it to move it into the entry area. You can also use the standard search keys and buttons to move from line to line within the entry area. Clicking on the First button (or pressing F5) brings in the first sequence; clicking on the Last button (or pressing F6) brings in the last sequence. You can advance forward a line at a time by clicking on the Next button (or pressing F8) and you can move backwards a line at a time by clicking on the Previous button (or pressing F7). Once a line is in the entry area, press <Enter> to advance through the fields. Make any changes, then click on the Save button (or press F10) to save the entry.
Using Specifications Templates
When entering a routing you can access specifications templates from the Notes screen by pressing the <Home> key (or by clicking on the Enter Specs button). The specifications entry screen is presented. You can either enter specifications from scratch or you can copy in a template by clicking on the Copy Spec Templates button (or press F2) to display templates in a pop-up window. Highlight the desired template and press <Enter> or click on it and the template's pre-defined fields will come into the screen. You can then complete the information required for this particular routing sequence. For more information on specifications templates, see Field Explanations above.
Copying Sequences from another Item number
You can copy all the sequences from one item number to another. Often many products share the same routing sequences with only minor differences. It is much faster to use one product's routing as a template to copy from and then edit the new routing for any differences.
To do so, enter the item number of the source item number from which you wish to copy or select it by clicking on the Lookup button (or press F2). When the cursor is in the description field, click on the Copy Routing button (or press F3). You are asked if you wish to copy all the sequences from this product to another. If you answer yes, you are prompted for the item number of the product to which you want to copy all the sequences. Enter the target item number and press <Enter>. All the sequences will copy over and the new routing will be on the screen, ready for editing.