a. The top level of a Job/Work Order must be able to link to its Sales Order, unless it is a Make-To-Stock Work Order.
b. Each level of a multi-level Job/Work Order must be linked to its Parent Job/Work Order, unless it is a Make-To-Stock Work Order.
c. All levels of a multi-level Job/Work Order must be linked to its Sales Order, unless it is a Make-To-Stock Work Order
2. Provide a Traditional Traveler (shop paper) with a Material Requirements List, Operation Sequences and Operation descriptions
a. Material Requirements List for the Work Order in Operation sequence with the Planner's recommended Raw Material Lot - bar-coded for material Issues with a dropdown List for Lot selection, Operation and Work Center to be delivered to
b. The Traveler heading would contain Customer ID, Customer Name, Customer PO, Sales Order/Line Item/Release, Customer Part & Description, Parent Job #, its own Job, Due Date, Release Quantity, Job Part & Description
c. The body of the Traveler would consist of the Operations printed in Operation sequence along with any (Material, Tool, Fixture or Note) required by the Operation, Work Center, Work Center Description, Estimated Set-Up and Run Time, Operation overlap (# of pieces or time), bar-coded for Labor Reporting
1) Bill of Material Dimensions would print beneath the Material line, if they were Dimensioned Raw Materials
3. Provide Job Tickets/Cards for identification and Operation level Bar-coded Labor Reporting on Overlapped Operations or when units Move ahead of the rest of the Job Lot
a. Printed on light card stock or perforated paper
4. Provide for Notes at the Job, Operation and Materials levels - see Req # 9 in IT Requirements
5. Provide for the splitting of multi-level Jobs from any level of the Job, just NOT from the top
a. The result of the split should be straight-forward and predictable: 1) If the original Job's Release Quantity = 550 and the split is for 100 at the 4th of 10 Operations, 100 units = 18.18 % of the 550 units:
a) Operations prior to the "split at" Operation should have their Estimated & Actual Costs, Operation units Completed and Scrapped Split 81.82% vs. 18.18%, rounding in a consistent manner
b) If the split quantity is greater than the Completed Quantity at the 4th Operation, then the Split Job will require an estimated Set-up on its 4th Operation and enough estimated Run-Time to complete the quantity difference, as well as the required Tooling and Fixturing used at the 4th Operation
c) Any down-stream Operations on the Split Job must have Set-Up times = the original Job's and proportionate Run-Times
b. Complete Job Split information is required on both the Original Job and the Split Job:
1) On the original Job after the Split:
a) Split Job #
b) Split Operation #
c) Split Date & Time stamp
d) Split User ID
2) On the Split Job:
a) From Job # & Operation
b) Split Date & Time stamp
d) Split User ID
6. The Plant Shop Calendar by Facility will be the default to all Departments, Work Center Groups, Work Centers and Machines at that Facility:
a. The default Shop Calendar can be overridden at the Department, Work Center Group Work Center and Machine level with individual unique Shop Calendars.
7. The Plant Shift (Start/Stop Times by day of the Week) definitions by Facility will default to all Departments, Work Center Groups, Work Centers and Machines at that Facility
a. The default Shift definitions can be overridden (for a Start & Stop date range) at the Department, Work Center Group, Work Center and Machine level
1) The Capacity per Shift will default to the amount of time in the Shift definition, based on the Shift's Start and Stop Time. This can be overridden to reflect efficiency of less than 100%
b. Operations must have a Start Date & Time and a Stop Date & Time
8. Provide for Work Center hierarchy by Facility of Department, Work Center Group, Work Center and Machine:
a. Departments make the organizing of reports easier
b. Maintaining Routings at the Department or Work Center Group and then Dispatching a Job's Operation to a specific Work Center or Machine makes life a lot easier (realistic)
1) A Job/Work Order should be prevented from being Realesed, if an Operation has not been dispatched to a Work Center or Machine
c. Each level in the hierarchy will carry the sum of their lower level's daily Capacity and number of children (Machine Groups & Machines)
d. Provide for Move & Que Days by Work Center which would copy into the Routing and Job/Work Order Operations
9. Provide for graphical Click & Drag Operation Dispatching
10. Provide default Labor, Labor Overhead (Fixed & Variable), Machine Overhead (Fixed & Variable) rates ($/Hr) by Department for Job Cost Estimating, as well as, Estimates for Customer Quotes
a. These default rates can be overridden at the Work Center Group, Work Center or Machine levels
11. Provide a System Parameter allowing Labor Rates to be charged at Estimate/Standard or at Employee specific
12. Quantity (Complete, Scrapped & Moved), Labor, Machine and Overhead costs are to be charged to the Job's/Work Order's Operation (On-line Real-Time), when the Labor Transaction is created via keyboard or Bar-Code Data Collection
13. Quantity Scrapped is to be a sub-set of Job Cost, calculated based upon the Operation at which they were scrapped which includes their share of the prior Operations' cost plus their share of the Costs to date at their current Operation This should be consistent across all costing methods
14. Quantities received into Stock from a Job/Work Order ahead of the rest of the Job's Quantity should be costed in a manner consistent with that of REQ # 13
15. Provide a System Parameter to determine the Closing/Completing of a Job's/Work Order's Operation, providing for the follwing senarios:
a. When Quantity Completed + Quantity Scrapped at an Operation equals or exceeds that Operation's Scheduled Quantity
b. When the Quantity Completed at an Operation equals or exceeds that Operation's Scheduled Quantity
c. Manual Closing via Labor Reporting or direct edit of the Operation's Status Code
16. Provide a screen/form which displays those Jobs that are eligible for Closure/Completion, based on some or all of the follwing:
a. All of a Job's Operations are Closed
b. The Quantity Received off of the Job equals or exceeds the Job's Release Quantity
c. The Quantity Received off of the Job plus Quanity Scrapped equals or exceeds the Job's Release Quantity
1) By simply selecting a listed Job, it's Closed/Completed, immediately
17. Data Collection (on-line real time updates):
a. Provide a reasonably complete dialogue with the User for on-line prompting
b. Provide for Piece Count reconciliation such that a Quantity Completed that is greater than the prior Operation's Quantity Completed will be challenged
c. Provide for Piece Count reconciliation such that a Move Quantity cannot EXCEED that Operation's Quantity Completed:
1) If the Move Quantity entered + the Operation's Move Quantity MATCH the Operation's Quantity Complete, the User should be prompted to optionally Close/Complete the Operation, unless the System Parameter is set to automatic Closing/Completion
d. If the (Quantity Complete being entered + that Operation's Quantity Complete) EXCEEDS the Job's Release Quantity, display a message challenging the quantity
e. After the User has completed their transaction, they will be prompted to check their data before finally transmitting the transaction
f. Provide for the Supervisors to be able to assign Employees to Job Operations
g. Provide for Supervisors to see who is here, their assignments and/or what Jobs they are currently working on for the Supervisor's Department, Work Center Group, Work Center.or Machine
18. Provide the following status and tracking data by Job
a. Created Date, Time & User ID
b. Release Date, Time & User ID
c. Last Manual Change Date, Time & User ID
d. First Printed Date, Time & User ID
e. Last Printed Date, Time & User ID
f. Closed/Completed Date, Time & User ID
g. Re-Opened Date, Time & User ID
h. Last Labor Transaction Date & Time
i. Last Receipt to Stock Date & Time
19. Provide Job Inquiry capability by Job, Part, Customer, Department, Work Center Group, Work Center or Machine as the filter:Provide Job Inquiry capability by Job, Part, Customer, Department, Work Center Group, Work Center or Machine as the filter:
a. Once a Job has be selected form the list of Jobs retreived, display the following for the Job and its Sub-Jobs:
1) Operation Status (Open/Closed/Hold), Quantities (Complete, Scrapped, Moved), Estimated Costs (material, outside service, labor & overhead), Actual Costs, Estimated Set-Up & Run Times, Actual Set-Up & Run Times
2) Component (material, fixture, tool, outside service) status - required quantity, quantity issued, estimated cost, actual cost
a) If a Component is referenced to a Purchase Order and Line Item, be able to link to the PO and display it
3) If the Job is referenced to a Sales Order Line/Release, be able to link to the Sales Order and display it. 20. Provide for the cost reconciliation of multiple Operations being worked on simultaneuosly by the same Employee, based on Start/Stop Times
21. Provide for the typical SFC reports (Dispatch Report, Operations Past Due By Work Center, Jobs Past Due, Operation Piece Count Reconcilliation, Job Cost & Performance)
22. Provide for Indirect Jobs for meeting, training, etc. - the labor reporting for these Indirect Jobs would not impact WIP
a. It would be highly desirable if the Scheduled attendance of Employees on an Indirect Job could reduce their availability for Scheduling Capacity
23. Provide for the Scheduling and Costing of Maintanance Jobs which would reduce the available Capacity of the Work Center/Machine being maintained without impacting WIP
24. Provide for Rework Jobs that become part of the original Job's Job Cost via cross-referencing the Rework Job to the original JobProvide for Rework Jobs that become part of the original Job's Job Cost via cross-referencing the Rework Job to the original Job:
a. The resulting Journal Entries from the Rework Job would be directed to specified General Ledger Accounts, based on Product Code
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