Advanced Repetitive

Repetitive schedules perform the same functions as work orders in a process environment. This chapter discusses how repetitive schedules are created and exploded, and how inventory is issued when the process is complete.

Introduction to Advanced Repetitive
Outlines the uses of repetitive scheduling, explains the different uses of the Repetitive and Advanced Repetitive modules, and describes the unique features of Advanced Repetitive.

Setting Up Advanced Repetitive
Lists the data that must be defined and set up before running Advanced Repetitive and explains how to set up different aspects of Advanced Repetitive.

Simulating Schedules in the Workbench
Describes when and why to create simulated schedules with Line Schedule Workbench (18.22.1.10) and addresses specific screens and functions within that program.

Creating Repetitive Schedules
Describes how to create repetitive schedules in different ways.

Exploding Repetitive Schedules
Explains when and how to use Schedule Explosion (18.22.2.4).

Using Repetitive Picklists
Explains when and how to use Repetitive Picklist Calculation (18.22.3.1), troubleshooting, picklist printing, and inventory transfer.

Managing Cumulative Orders
Explains how to use Cumulative Order Create (18.22.11), Cumulative Order Close (18.22.10), and Cumulative Order Maintenance (18.22.6).

Executing Repetitive Transactions
Describes the data used by repetitive transactions, why warning messages appear, and explains rate variances, method change variances, and repetitive transaction programs.

Managing Subcontracting
Outlines how to set up scheduled orders, ship subcontract items, and receive completed subcontract items.

Repetitive manufacturing is executed with schedules rather than work orders. Schedules require fewer steps and less paperwork to execute and are typical in manufacturing environments that use assembly lines to produce similar products using the same process. Since the same activities are repeated regularly, there is little variation.

• Build to a repetitive schedule.

• Run a production line without finite schedules.

• Run a production line with repetitive schedules, forward scheduled to capacity limits.

• Report production and let MRP adjust inventory plans.

The system provides two ways of managing repetitive production, appropriate in different business environments. The Repetitive module works well when one or more of the following is true:

• Manufacturing lead times are relatively short and batches do not overlap.

• All work in process is complete by the end of each day.

• Work-in-process (WIP) costs are either insignificant or fairly constant.

• The routing does not include subcontract operations.

The Advanced Repetitive module supports manufacturing environments where the following apply:

• Manufacturing lead times are long.

• Continuous processing is in use; lines are dedicated to one item for days, weeks, or months.

• WIP costs are variable or high.

• Subcontracting operations are managed in a release management (just-in-time) environment.

• Batches can overlap and visibility of and control over WIP are necessary.

Note: The PRO/PLUS WIP Lot Trace (WLT) module affects some features of the Advanced Repetitive and Repetitive modules. If you are using the optional PRO/PLUS module, WIP Lot Trace is available as menu option 3.22.13. When activated, additional frames display in some programs. The discussion in this chapter assumes that WLT features are not active. For details, see User Guide: PRO/PLUS.

Advanced Repetitive provides features that are not available in the basic Repetitive module.

• Ability to post usage variances without having to close a cumulative order.

• Ability to close a cumulative order and transfer work-in-process (WIP) balances to a new cumulative order for easy phase-in of product structure or routing changes. This also supports accounting period cutoffs.

• Automatic start and end effective date assignment for cumulative order expiration dates.

• Expanded WIP inventory visibility and control.

• Addition of WIP accumulators to track cumulative work moved, rejected, reworked, scrapped, and adjusted.

• Scrap or adjust from either the input, output, or reject queue.

• Record multiple scrap, reject, and rework quantities with reason codes.

• Generate analysis reports, scrap and adjustments usage variance reports, and scrap and adjustments valuation reports.

• Integration of supplier scheduled orders with Advanced Repetitive supports repetitive purchasing of subcontract services.

• Subcontract shippers let you create shipment paperwork and register the physical shipment of materials to the subcontractor.

• Using EDI eCommerce to support electronic data interchange (EDI) transactions lets you receive an advance ship notice (ASN) from your supplier to register the receipt of processed materials.

• The Backflush Transaction (18.22.13) and subcontract processing activities let you use non‑milestone backflushing.

• Non‑milestone backflushing uses a demand-pull strategy to determine the units needed from non‑milestone operations. The amount depends on the net requirement of the processing milestone operations. The net requirement is satisfied by consuming units in the output and input queues of preceding non‑milestone operations until either the requirement is satisfied or another milestone operation is encountered.

• You can use any repetitive transaction at a non‑milestone operation.

• In Advanced Repetitive, the earliest open schedule is always consumed—not just completions over the scheduled quantity for that date.

• Cumulative Completed Maintenance (18.22.2.6) lets you modify the quantity completed on a repetitive schedule. Changes to a schedule’s cumulative completed are reapplied to the schedule using the consume-earliest-open logic.

• WIP inventory is visible to the Schedule Explosion (18.22.2.4) and MRP programs. This prevents overplanning for components that might result from not including WIP.

• Schedule Delete (18.22.2.7) enables easy deletion of repetitive schedules and their planned work orders. Limit schedule consumption in the past by deleting schedules left open that fall before a specific date. In Schedule Delete, the date defaults to Monday’s date. Use this to establish the earliest open schedule.

Many activities in the two modules are exactly the same or similar. This chapter describes how to use Advanced Repetitive. topic describes the features of basic Repetitive that differ.