Production Management Options

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Set up the Production Management module

Overview

 

Set Up User-Defined Codes

Fields

 

 

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Integrating Production Management with Other Modules

 

 

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Select Production Management Setup menu > Production Management Options.

Overview

Use Production Management Options to set up the module in the way that most fits your business. Included are settings that allow you to:

Fields

 

Select the cost to use as the default unit cost for inventory items assigned to a work ticket or work ticket template. The default unit cost is multiplied by the required quantity to calculate material budget costs.

  • Select Last to assign the last cost in Item Maintenance as the default unit cost.
  • Select Standard to assign the standard cost in Item Maintenance as the default unit cost.
  • Select Average to assign the average cost for the selected warehouse code as the default unit cost.

Note The following exceptions occur regardless of the selection in this field.

  • When an inventory item is assigned the standard cost valuation method, the standard cost is the default unit cost.
  • An inventory item's default last cost is used in the Cost field on the Work Ticket Entry Materials tab if the Purchase check box is selected.
  • If the Dynamic Materials check box is not selected and a Quantity Used value is recorded for an inventory item in a work ticket, the Extended Cost amount is calculated by multiplying the default unit cost by the recorded quantity used.

Select this check box to post work ticket material issue transactions in detail by work ticket to the General Ledger Daily Transaction file.

Material usage postings are generated during the Daily Materials Usage Register/Update.

Clear the check box to post issue transactions in summary by General Ledger account.

Select this option to post labor cost transactions in detail by work ticket to the General Ledger Daily Transaction file.

Labor cost postings are generated during the Labor Entry Register/Update and Periodic Labor Register/Update.

Clear the check box to summarize labor cost postings by General Ledger account.

Enter the number of years to retain work ticket history. You must retain work ticket history for at least two years.

The history will be retained for the number of years entered or until you run the Purge Work Ticket History utility.

Select the current calendar year or fiscal year.

This field appears as either Current Calendar Year or Current Fiscal Year, depending on the option selected in the Base Inventory Periods On field in Inventory Management Options.

For the Current Fiscal Year option, you can click the Lookup button to list all fiscal years.

If the Inventory Management module is not installed, this field defaults to Current Fiscal Year set in General Leger Options.

Select the current Production Management accounting period.

This field defaults to the current General Ledger accounting period but it can be changed.

Select this check box to integrate Production Management with the Accounts Payable module.

When the modules are integrated, cost distributions can be assigned to open and closed work tickets in Accounts Payable Invoice Data Entry and Manual Check and Payment Entry.

Clear the check box if you don't want to integrate the two modules.

This field is available if the Accounts Payable module is activated.

Select this check box to integrate Production Management with the Purchase Order module.

When the modules are integrated, purchase orders can be created from Work Ticket Entry, and items assigned to open purchase orders can be linked to open work tickets in Purchase Order Entry.

Clear the check box if you don't want to integrate the two modules.

This field is available if the Purchase Order module is activated.

Select this check box to integrate Production Management with the Bill of Materials module.

When the modules are integrated, you can:

  • Assign templates and steps to bill numbers and bill options in Bill of Materials Maintenance
  • Create work tickets by copying from bills
  • Import materials from bills

Clear the check box if you don't want to integrate the two modules.

This field is available if the Bill of Materials module is activated.

Select an option to specify how Production Management integrates with the Payroll module.

  • Select Yes to integrate Production Management with Payroll. When the modules are integrated, Payroll employees, departments, and earnings codes are used in Production Management.

    Labor Entry records can be imported into the Payroll module for use in Payroll Data Entry.

    Note Overtime is imported into Payroll Data Entry as entered in Labor Entry. Overtime earnings are not automatically calculated if earnings exceed regular weekly earnings.

  • Select No if you don't want to integrate Production Management with the Payroll module. When the modules are not integrated, departments, employees, and earnings codes will have to be set up in Production Management.

  • Select Employees Only to use Payroll employees and earnings codes when entering labor transactions in Labor Entry.

    Departments and employees must be created and maintained in the Payroll module. Earnings codes can be copied from the Payroll module and maintained in P/M Earnings Codes Maintenance. You will not have the option to import Labor Entry data into Payroll.

This field is available if the Payroll module is activated.

The PR Sync button appears if Yes or Employees Only is selected in the Payroll integration field. Click this button to copy Payroll employees, earning codes, and departments to Production Management.

Note If the Production Management module is integrated with Payroll, and you change this setting to No, any earnings codes with a type that is used only in the Payroll module will be changed to a type of Miscellaneous. If you then change back to either Yes or Employee Only, the earnings codes will change back to their original type.

Enter an abbreviated description to customize the default text used on reports and screens throughout the module.

Important: Any changes to these descriptions are system-wide for all companies, and your labels will be different than what is described in the help and other documentation.

Enter a description to customize the default text used on reports and screens throughout the module.

Important: Any changes to these descriptions are system-wide for all companies, and your labels will be different than what is described in the help and other documentation.

This field indicates that batch processing is available for Transaction Entry and Labor Entry, and it can only be viewed.

Select the check box to allow batch processing for Work Ticket Transaction Entry and Labor Entry. Clear the check box to not allow batch processing.

Enter the next batch number to assign when using the batch processing feature in Transaction Entry and Labor Entry. You can enter numeric or alphanumeric characters.

This field is available only if the Enable check box is selected for the corresponding task.

Enter a default warehouse code representing the main location for finished goods or click the Lookup button to list all warehouse codes.

Clear this field to use the warehouse code selected in the Default Warehouse Code field in Inventory Management Options.

This field is available when the Require Multiple Warehouses check box is selected in Inventory Management Options.

The warehouse code selected in this field is automatically entered in the Parent Whse field on the Work Ticket Entry Header tab if: 

  • A default parent warehouse code is not selected in the Default Values for Work Ticket Entry window for the current user and...
  • The Use Item Default Warehouse for Parent Item check box in Production Management Options is not selected.

Enter a default warehouse code representing the main location for work ticket materials, or click the Lookup button to list all warehouse codes.

Clear this field to default the warehouse code selected in the Default Warehouse Code field in Inventory Management Options.

This field is available when the Require Multiple Warehouses check box is selected in Inventory Management Options.

The warehouse code selected in this field is used in the Materials Whse field on the Work Ticket Entry Header tab if: 

  • A default materials warehouse code is not selected in the Default Values for Work Ticket Entry window for the current user and...
  • The Use Item Default Warehouse for Materials check box in Production Management Options is not selected.

Select this check box to use the default item warehouse code defined in Item Maintenance when creating a work ticket, instead of the warehouse code entered in the Default Values for Work Ticket Entry window or the Default Warehouse for Parent Item field in Production Management Options.

Clear the check box to use the warehouse code selected as the parent default warehouse code in the Default Values for Work Ticket Entry window or the Default Warehouse for Parent Item field in Production Management Options.

This field is available when the Require Multiple Warehouses check box is selected in Inventory Management Options.

Select the check box to use the default item warehouse code defined in Item Maintenance when creating a work ticket, instead of the warehouse code entered in the Default Values for Work Ticket Entry window or the Default Warehouse for Materials field in Production Management Options.

Clear the check box to use the warehouse code selected as the materials default warehouse code in the Default Values for Work Ticket Entry window or the Default Warehouse for Materials field in Production Management Options.

This field is available when the Require Multiple Warehouses check box is selected in Inventory Management Options.

Enter a work ticket class to use as the default entry in the W/T Class field on the Work Ticket Entry Header tab when a work ticket is created and a default work ticket class is not selected in the Default Values for Work Ticket Entry window for the current user.

Clear this field to not default a work ticket class.

Select the check box to consider required materials assigned to open work tickets as demand on inventory.

If this check box is selected, the Req for WT field in the Quantities section on the Item Maintenance Main tab displays required quantity values for materials assigned to open work tickets.

Clear the check box if you don't want to consider required materials assigned to open work tickets as demand on inventory. The Req for WT field in the Quantities section on the Item Maintenance Main tab will not display required quantity values for materials assigned to open work tickets if this check box is cleared.

Note This check box must be selected to allow users to create purchase orders from Work Ticket Entry.

Select this check box to automatically select the Explode Subassemblies check box in the Work Ticket Entry Copy From window when user defaults are not established in the Default Values for Work Ticket Entry.

Clear the check box to automatically clear the Explode Subassemblies check box in the Work Ticket Entry Copy From window when user defaults are not established in the Default Values for Work Ticket Entry.

This field is available when the (Integrate with) Bill of Materials check box is selected.

Enter the general ledger account number or click the Lookup button to view a list of all general ledger accounts.

This account is used during the Work Ticket Transaction Register update when a Completion transaction is entered for a work ticket and the parent item is a special item.

If the Dynamic Materials check box is selected, the account used during the Daily Materials Usage Register update for a material issue of a special item is determined as follows:

  • The Special Item Inventory account entered in Work Ticket Class Maintenance is used. The account field is required, so this is mostly like the account that will be used.
  • If that account field in Work Ticket Class Maintenance is blank, the Special Item account from Purchase Order is used.
  • If that account is blank, the Special Item Purchases account in this field is used.

Enter the next work ticket number to assign when clicking the Next Work Ticket No button in Work Ticket Entry.

Enter the next transaction number to assign using the Automatic Transaction Number feature in Work Ticket Transaction Entry.

Select this check box to allow the automatic creation of labor transactions for work tickets when they're released. Clear this check box if you do not want to automatically create labor transactions.

For more information, see Issue Methods.

Select this check box to allow automatic generation of material issue transactions for components when work tickets using the Automatic issue method are released in Work Ticket Transaction Entry.

Clear the check box if you do not want to generate material issue transactions automatically.

Select this check box to allow the automatic selection of the Backflush Labor check box in Work Ticket Class Maintenance.

Select this check box to allow the automatic selection of the Backflush Material check box in Work Ticket Class Maintenance.

Select this check box to limit the automatic issue of materials to the quantity on hand. Clear this check box to automatically issue materials even if the quantity required exceeds the quantity on hand.

This check box is available if the Allow Auto Issue Materials check box is selected.

Select the default entry for the Cost Completion Method field in Work Ticket Class Maintenance for make-to-stock work tickets.

The selected completion method determines which costs are used to calculate the completion unit cost.

NOTE: Labor and transactions are automatically created for work tickets if Automatic or Backflush is selected in Work Ticket Entry.

  • Actual:  The completion unit cost is based on the costs updated to the Work in Process accrual account.

Work tickets created with the Manual or Backflush issue method have a zero balance in the Work in Process accrual account after each completion entry is recorded. Whether the cost in the Work in Process accrual account represents the full-planned quantity or a partial quantity, the system assumes that all costs applicable to the completion entry are entered and that the cost in the Work in Process accrual account represents only that completion entry.

Work tickets created when Automatic is selected in the Issue Method field in Work Ticket Entry use the work ticket percent-complete amount to allocate the costs updated to the Work in Process accrual account before the completion entry is recorded. This method leaves a zero balance in the Work in Process accrual account when the last completion entry for the work ticket is recorded.

  • Budget:  The completion unit cost is based on the revised budget of the work ticket at the time of completion in Work Ticket Entry. The work ticket percent complete is used to calculate the cost for each completion.

    The Budget cost completion method may create a positive or negative balance in the Work in Process accrual account if Auto Issue Material and Auto Issue Labor are selected in Work Ticket Entry and the automatically created material and labor processing transactions are edited. The automatically created transactions are based on the budget costs (calculated when the work ticket is created), and if they are edited, the variances between the standard costs and the edited costs are posted to the Work in Process accrual account. These variances are ignored by the completion calculation, which always uses the standard costs.

  • Lower of Budget/Actual: This method checks each step of the work ticket to determine if the budget or the actual cost is lower. The lower cost for each step determines which method is used to calculate the completion costs. If the Budget cost is lower, the completion cost is calculated using the Planned Cost Completion method. If the actual cost is lower, the completion cost is calculated using the Actual Cost Completion method. This method leaves a zero balance in the Work in Process accrual account when the last completion entry for the work ticket is recorded.

  • Standard: This method uses the standard cost assigned in Item Maintenance.

Select this check box to enable the auto release of work tickets. You must also select the work ticket class associated with an auto release. After an open work ticket is saved, the work ticket is automatically released.

Select this check box to enable the Dynamic Materials feature.

When this feature is enabled, the following occurs in Inventory Management for inventory items in a purchase order linked to work tickets.

  • The quantities are received into inventory and then immediately relieved.

  • The quantity on purchase order value for the inventory item is reduced.

  • The quantity on hand is increased and then immediately relieved.

  • Transactions for both the receipt and the issue of the items are recorded in the transaction detail file for the inventory item.

  • For LIFO or FIFO items, the tier created during the receipt is immediately relieved.

  • For lot or serial items, the lot or serial numbers() to which the receipt was distributed are relieved.

  • Because of the in-and-out nature of the transaction, the inventory item’s average cost and warehouse average cost are not recalculated.

In addition, the following occurs in Production Management:

  • Receipt information is captured.

  • The quantity used on work tickets is increased.

  • An issue transaction is created in the work ticket detail transaction file.

  • If an overhead percent or amount value is assigned to the work ticket class, the calculated overhead is included in the issue transaction overhead amount field.

  • A transaction is created in the Daily Materials Usage log. Access the Daily Materials Usage Register/Update option from the Main Menu in Production Management.

    Important When the Dynamic Materials feature is enabled, the General Ledger account associated with a purchase order item linked to a work ticket should not be changed.

    The Daily Receipt Register update process uses the Purchase Order posting date entered in the Daily Receipt Registers/Update window to record the inventory transaction detail record and for the general ledger transaction.

    The Purchase Order posting date is also used to record the Dynamic Materials transaction to the Daily Materials Usage Log and to create the issue transaction in the inventory transaction detail record. The Purchase Order posting date is used for all transactions to avoid possible problems with inventory reconciliation.

When the Dynamic Materials feature is not enabled, the following occurs for inventory items in a purchase order that are linked to a work ticket: 

  • A receipt of goods is recorded in Inventory Management.
  • The quantity received is incremented in the item’s warehouse detail file.
  • The quantity on the purchase order is reduced.
  • The quantity used for the work ticket part is increased in the work ticket.

And the following occurs for miscellaneous and special items in a purchase order that are linked to a work ticket.

  • A receipt of goods is recorded for the purchase order.
  • The Daily Receipt Register/Update does not create general ledger postings.
  • The quantity used for the work ticket part is increased and recorded in the work ticket.

Select this check box to summarize material lines with the same step number, item number, and scrap percentage on one line in Work Ticket Entry when the parent item bill has options or the template has materials.

Clear this check box to have multiple material lines created for the same steps, items, and scrap percentage on the Work Ticket Entry Materials tab.

Select this check box to combine all unique comments from the summarized material lines at the Comment field on the Work Ticket Entry Materials tab.

Clear this check box to display only the last comment from the summarized materials lines at the Comment field on the Work Ticket Entry Materials tab.

Note This check box is available only if the Summarize Material Lines by Step and Item check box is selected.

Select this check box to print a work ticket form when work tickets are released from Work Ticket Entry or when multiple work tickets are released using the Auto Release function.

Select this check box to print material information on the work ticket form.

Select a material print format.

  • Select Materials First to print all of the material information together on the work ticket form, followed by the steps.
  • Select Materials Mixed to print each step with the associated materials directly beneath it.

This field is available if the Print Material on Work Ticket check box is selected.

Select the default option for the Print Labels field in the Default Values for Work Ticket Entry window.

  • Select None to omit labels from work tickets.
  • Select Lot Items to print labels for lot items only.
  • Select Serial Items to print labels for serial items only.
  • Select Both Lot & Serial Items to print labels for both lot and serial items.
  • Select All Items to print labels for all items.

Select a method for printing picking sheets.

  • Select Sort by Warehouse to print picking sheets sorted by both warehouse and work ticket number.
  • Select Sort by Work Ticket to print picking sheets sorted by work ticket number only.
  • Select None to not print picking sheets.

Select this check box to sort items by bin location on picking sheets. Picking sheets will be sorted by step number and then by bin location.

Clear this check box to sort items by item code.

This field is available only if Sort by Warehouse or Sort by Work Ticket is selected in the Print Picking Sheets field.

Select this check box to print each step number of the picking sheet on a separate page.

Clear this check box to print multiple steps per page.

This field is available only if Sort by Warehouse or Sort by Work Ticket is selected in the Print Picking Sheets field.

Select this check box to automatically print a picking sheet when work tickets are released during Work Ticket Entry.

Clear this check box to manually select work tickets for which picking sheets are printed.

This field is available only if Sort by Warehouse or Sort by Work Ticket is selected in the Print Picking Sheets field.

Select an option for displaying messages as reminders to print the Completion Missing Cost Report.

  • Select Yes to display a message to print the report after completion transactions are updated by the Daily Work Ticket Reports/Update.
  • Select No to hide the message.
  • Select One per Page to display a message to print the report after completion transactions are updated by the Daily Work Ticket Reports/Update. Work tickets will print on separate pages.

NOTE: If Yes is selected in the Print Missing Cost Report field in both the Completion Options and Close Options sections and completion and close transactions are entered for the same work ticket, only the Close Missing Cost Report prints.

Enter the percentage used to indicate a missing cost entry.

A completed work ticket shows cost variances less than the planned cost, and if the variance is equal to or greater than the percentage entered here, it is printed on the Completion Missing Cost Report.

This field is available if Yes or One per Page is selected in the Print Missing Cost Report field.

Select an option for printing the Completion Variance from Standards Report.

  • Select Yes to display a message to print the report after completion transactions are updated by the Daily Work Ticket Reports/Update.
  • Select No to hide the message.
  • Select One per Page to display a message to print the report after completion transactions are updated by the Daily Work Ticket Reports/Update. Work tickets will print on separate pages.

Enter the percentage that a work ticket must vary to be included on the Completion Missing Cost Report .

A completed work ticket with a variance from the planned cost that is equal to or greater than the percentage entered here is printed on the report.

This field is available if Yes or One per Page is selected in the Print Missing Cost Report field.

NOTE: If Yes is selected in the Print Missing Cost Report field in both the Completion Options and Close Options sections and completion and close transactions are entered for the same work ticket, only the Close Missing Cost Report is printed.

Select this check box to print the Back Order Fill Report after a completion transaction made for a back-ordered sales order or work ticket is updated by the Daily Work Ticket Reports/Update.

Select this check box to include work ticket component requirement information on the Back Order Fill Report.

This check box controls whether the information prints on the Back Order Fill Report in this module and in the Sales Order, Inventory Management, and Purchase Order modules.

This check box is available if the Print Back Order Fill Report check box is selected.

Enter the number of days in the future that work ticket component requirements will print on the Back Order Fill Report.

This field is available only if the Print WTs on Back Order Fill Report check box is selected.

Select an option for printing the Closed Missing Cost Report.

  • Select Yes to display a message to print the report after close transactions are updated by the Daily Work Ticket Reports/Update.
  • Select No to hide the message.
  • Select One per Page to display a message to print the report after close transactions are updated by the Daily Work Ticket Reports/Update. Work tickets will print on separate pages.

NOTE If Yes is selected in the Print Missing Cost Report field in both the Close Options and Completion Options sections of this tab and both completion and close transactions are entered for the same work ticket, only the Close Missing Cost Report is printed.

Enter the percentage used to indicate a missing cost entry.

Completed work tickets with a cost variance less than the planned cost are printed on the Close Missing Cost Report if the variance is equal to or greater than the percentage entered here.

This field is available only if Yes or W/T per Page is selected in the Print Missing Cost Report field.

Select an option for printing the variance from standards report.

  • Select Yes to display a message to print Close Variance from Standards Report after a close transaction is updated by the Daily Work Ticket Reports/Update.
  • Select No to hide the message.
  • Select One per Page to print Work tickets on separate pages.

Any closed work ticket with a cost variance from the planned cost is printed on the Close Variance From Standards Report if the variance is equal to or greater than the percentage entered in the Minimum Variance Percent to Print field.

NOTE: If Yes is selected at both the Completion Print Variance from Standards Report and Close Print Variance from Standards Report fields, and if completion and close transactions are entered for the same work ticket, only the Close Variance from Standards report prints.

Enter the percentage that a work ticket must vary in order to be printed on the Close Variance From Standards Report.

Any closed work ticket that has a cost variance from the planned cost prints on the report if the variance is equal to or greater than the percentage entered in this field.

This field is available if Yes or One per Page is selected in the Print Variance from Standards Report field.

Select an option for printing the work ticket Close Cost Ledger.

  • Select Yes to display a message to print the ledger after a close transaction is update by the Daily Work Ticket Reports/Update.
  • Select No to hide the message.
  • Select One per Page to print the ledger with work tickets on separate pages.

Select how the Auto Issue Material Shortage Report will be sorted.

  • Select Sort by Item Code to sort the report by material item code.
  • Select None if you do not want to print the report.

This field is available if the Auto Issue Material check box is selected.

Select one or more check boxes to view the corresponding source documents in Work Ticket Entry after using the Quick Print feature.

Clear the check boxes to return to the data entry window with no record selected.

The Picking Sheets check box is available if an option other than None is selected in the Print Picking Sheets field on the Forms tab.

NOTE Clearing any of these fields will display a new work ticket after using Quick Print.

Select this check box to display a prompt to print a picking sheet after printing a work ticket using the Quick Print feature.

This field is available if an option other than None is selected in the Print Picking Sheets field on the Forms tab.

Select this check box to bypass the printing window when printing a work ticket or picking sheet using the Quick Print feature.

Select one of the following options.

  • Select Yes to require that employees "punch in" when work begins on a work ticket step and "punch out" when work is completed. This option lets employees edit the start and end times until the labor transaction is updated.
  • Select No to require employees to enter the total amount of time worked on a work ticket step. Employees are not required to enter start and end times.
  • Select Only capture, no edit allowed to require that employees "punch in" when work begins on a work ticket step and "punch out" when work is completed. Start and end times are automatically captured based on the system date and time when the employee creates or completes a labor transaction. Employees are not allowed to edit start and end times.

Enter the smallest fractional hourly increment to allow for labor transactions.

For example:

  • To use a quarter of an hour as the smallest increment, enter .25.
  • To use a tenth of an hour as the smallest increment, enter .10.

Time entries are rounded to the nearest increment. This increment is also used during the Periodic Labor Update when calculated overtime is applied to work tickets.

Select this check box to allow the addition of regular labor (not overtime) to a closed work ticket. Adding labor to a closed work ticket results in a variance and updates historical records.

Select this check box to apply Labor and Labor Cost transactions to a work ticket when you click Accept to save the transaction in Labor Entry.

Clear this check box to apply labor transactions to a work ticket when the Labor Register is updated.

Note This field does not apply to Work Ticket Transaction Entry labor transactions.

Select this check box to establish punch in and punch out records based on labor start and end times.

This field is available if Yes is selected in the Capture Start/End Times in Labor Entry field.

Select this option to allow text entry describing the work performed when entering time worked against work tickets in Labor Entry.

Clear the check box if you don't want to allow text descriptions in Labor Entry.

Enter a code for a new code class.

You can create new classes to use in user-defined fields for work tickets.

Use the Delete Row button to delete a code class. Use the Reset Row button to clear the current row.

Note You cannot delete a code class if an associated code has been added in User Defined Info Codes Maintenance.

Enter a description for the code class.

Enter the number of characters allowed for the length of codes created under the code class.

Select a code type.

  • Select Alphanumeric to allow alpha-numeric characters for codes.
  • Select Numeric to allow only numeric characters for codes.

Enter the number of characters to use in the description field for codes assigned to this code class.