Process Product Change Orders
  PPT
Process Product Change Orders
Product Change Orders Process
This illustration is a suggested process sequence of master files for the Product Change Control module, for Product Change Orders, which is based on information that flows from one master file to another and prerequisites that need to be accomplished.
 
What is the procedure?
Who is responsible?
Create/Maintain PCO
Document Control
Review/Print PCO
Document Control
Route PCO
End User
Approve PCO
Approval Group
Release and Distribute PCO
Document Control
Incorporate PCO
Document Control
Implement PCO
Document Control
Create/Maintain PCO
Creating and maintaining PCOs is done in PCO Maintenance (1.9.2.13)
After completing the first screen, a menu will appear that gives you access to functions which allow detail modification of the product change order
Use your arrow keys to select a menu option
Each menu item (except Trailer Maintenance) leads to another menu
Select from the menu to bring up a screen to perform a function
Create/Maintain PCO
Product Change Order Structure
PCOs have three main parts
Header
Body (optional text)
Trailer
Changes are specified in the Body
We will discuss Item, Product Structure, Routing, and Item Spec changes
Formula and Process changes are optional to this discussion
PCO Maintenance
PCO creation can be broken down into the following steps:
Enter Header
Add Text (optional)
Specify Changes
Enter Trailer
Direct Item Master Access, a function under the Item File Maintenance Menu, gives you access to all items in the database. The modifications you perform using Direct Item Master Access take place in the item master files, not in the PCO.
Important: This function is the only function in PCO Maintenance that directly affects QAD SE production files.
Enter Header
Number the PCO document
Identify type and design group
Add any user-specific information
PCO Maintenance (1.9.2.13)
Number is filled in automatically if PCC Control (1.9.24) is set for Autonumbering
Break up large PCOs by assigning multiple PCOs with the same number and different IDs
Type and Design Group will determine approval cycle, distribution group, and autonumbering for the PCO number (if applicable)
The user-defined fields (highlighted in the picture above) do not affect processing and are optional fields
Select PCR/PCO Function Maintenance
A section menu allows you to complete other parts of the PCO
Only enabled processes appear on the section menu
Accessing PCO/PCR Function Maintenance allows you to
Change a PCO Number
Close a PCO to another PCO
Copy either to or from PCR/PCO to or from another PCO
Add Text
Adding text is optional
Manually enter or modify transaction comments
Copy Master Comments to PCO
Text Data Maintenance
Add, Modify, Delete PCO Text Files
Selection menu moves you to Text File Maintenance menu
Choose to create a new text file or modify or delete an existing text file
Add, Modify, Delete PCO Text Files
Works the same way as other transaction comments in QAD Standard Edition.
Copy Text from Master Comments into PCO
Selection menu moves you to Text File Maintenance menu
Choose to copy text from Master Comments
Master Comments Copy Selection
Enter master reference and type in a pop-up frame, or select from a list of comments.
Specify Changes
Identify the proposed changes considered on this PCO.
Item Data Maintenance
Proposed Item Master changes
Directly affects Production files
Possibly to enter new item numbers with Direct Item Master Access, rather than Item Data Maintenance (1.4.3), as part of a PCO
Note: Some companies require all Item Data Maintenance to be maintained through the PCC function, not through Item Data Maintenance (1.4.3).
Item Data Maintenance — Add, Modify, Delete PCO Data Files
Change existing items
Only one PCO per item
Does not support
Item-Site data
Item Planning data
Inventory data
Cost and price data
Exercise: Create a PCO with Item Changes
Important: The data used in these exercises may not be the same as the data shown in the screen captures in this lesson. You must have completed all the setup exercises before you can work on the processing exercises.
In the Item Master there are three types of Batteries, 30-100, 30-1000, and 30-10000. They are in product line 2000, Electronic Products. Your company procedures require you to route the changes through a PCO.
1 Use PCO Maintenance (1.9.2.13) to create a new PCO to route these proposed changes to the Item Master.
Let QAD SE assign the PCO number. The number will be assigned when you complete the Type and Design group fields and click Next.
2 Advance to the Type field and enter the following:
 
Field
Data
Type
PCO
Design Group
DESIGN
3 Write down the PCO number assigned for later reference: ____________________
4 Title and Reason fields are optional. Leave them blank, or create a simple description for this PCO:
 
Field
Data
Title
Change Product Line
Reason
All Batteries moving to Component Materials
5 Select Item Data Maintenance and then choose Add, Modify, Delete PCO Item Data.
a Add items:
 
30-100
RevB
30-1000
RevB
30-10000
RevB
b For each, set Comments to No.
c Change the Product Line on each to 6000.
d Verify the Item Type for each is = ELEC, and Group = ELECTRON.
6 Click Back, choose Trailer Maintenance.
a Using the Mandatory field, assign an implementation date no later than the last day of next month.
b Disposition: UAI; click Next, click Back.
7 Use PCR/PCO Detail Inquiry (1.9.2.8) to review your PCO to verify that your changes were all included.
Structure Data Maintenance
Copy product structures or where-used to the PCO to propose changes
Maintain changes with Detail Maintenance
Proposed component replacements throughout multiple bills
Note: You cannot delete a product structure from within PCO Maintenance since structures can contain “as of” information. Instead, deactivate the structure by entering an end-effective date. Because delete is not available, structure add and structure edit functions are separate. This distinguishes the structure maintenance functions in PCO Maintenance from all other maintenance programs.
Copy Product Structure into PCO
Specify Parent Item
Current Bill of Materials displays
Select or de-select items from the bill to copy into the PCO
Copy Where Used into PCO
Works the same as Copy Product Structure into PCO except:
Displays bill of material as indented where-used bill of material
Useful for making the same change to several product structures
PCR/PCO Detail Maintenance - Product Structures
Add items to product structures
Delete product structure records
Sets an end effective date when PCO is incorporated
Edit product structure changes
Replace Product Structure Component
Replaces one component item with another across multiple bills of material
Select the component in any previous Structure File Maintenance step
Searches product structure records already included in the PCO and sets end effective dates for replacements
Adds additional product structures to the PCO with the substitution
Other detailed product structure data is copied from the existing record
Exercise: Create a PCO with Product Structure Changes
The Magic Box assembly, 12-101 uses switch 12-105.The current product structure assumes that there is no scrap involved in the switch unit. Your recent experience shows a 5% scrap involved.
1 In this exercise, use PCO Maintenance (1.9.2.13) to create a new PCO to make this change.
Let QAD SE assign the PCO number.
 
Field
Data
Assign Type
PCO
Design Group
DESIGN
Write down the PCO number assigned for later reference: ____________________
 
Field
Data
Title
Add Scrap
Reason
12-101 to be modified: Component 12-105 shows 5% Scrap
2 Continue past the header. Choose Structure Data Maintenance. From this menu select Copy Product Structure into PCO.
a Parent Item = 12-101. Click Next.
b select 12-105 by clicking on the item number.
An asterisk appears when the component is selected.
Click Next then Back to complete the transaction.
3 From the menu choose Structure Data Maintenance and then PCR/PCO Detail Maintenance - Product Structures.
a When you arrow down, you should see that one record was copied into the PCO
(Parent Item = 12-101 and Component Item = 12-105). If you do not see this record, repeat step three above until the component is copied successfully.
b Deactivate should remain = No (Do not delete the component).
c Specify a 5% scrap. Accept all the remaining default fields. Click Next.
d Click Back, choose Trailer Maintenance.
a Using the Mandatory field, assign an implementation date no later than one month from today.
b Disposition: UAI, click Next, click Back.
4 Use PCR/PCO Detail Inquiry (1.9.2.8) to review your PCO to be certain your changes were all included.
Routing Data Maintenance
For both standard and rate-based routing
Copy routings to the PCO
Edit routings with Detail Maintenance
Both standard routings and routings that are rate based
Note: Processes are not maintained with this function
Copy Routing to PCR/PCO
Start with a copy of existing routing to simplify editing
Bring routing records into PCO for modification
Displays the operation for a routing to select which steps to include
PCR/PCO Detail Maintenance - Routing
Operations to a routing
Delete operation steps
Sets an end effective date when the PCO is incorporated
Edit routing changes
PCR/PCO Detail Maintenance - Routing (Rate Based)
Same differences as between standard Routing Maintenance (14.13.1) and Routing Maintenance (Rate Based) (14.13.2).
Exercise: Create a PCO with Routing Changes
1 In this exercise, use PCO Maintenance (1.9.2.13) to modify the routing for the 12-101 Magic Box Assembly to add a standard rework step.
Let QAD SE assign the PCO number.
 
Field
Data
Assign Type
PCO
Design Group
DESIGN
Write down the PCO number assigned for later reference: ____________________
2 Title and Reason fields are optional. Leave them blank, or create a simple description for this PCO:
 
Field
Data
Title
Adding Rework
Reason
12-101: Adding rework routing
Continue past the header.
3 Select Routing Data Maintenance, then enter the following in PCR/PCO Detail Maintenance - Routing:
 
Field
Data
Routing Code
12-101
Operation
30
Work Center
1010
Description
Rework as required
Milestone Operation
No
Comments
No
4 Save the record without adding any information to the trailer. Click Back, then Back.
5 Use PCR/PCO Detail Inquiry (1.9.2.8) to review your PCO and verify that the changes were all included.
Item Specification Maintenance
Copy quality records to PCO
Manage changes to the quality tests associated with an item
Copy Item Specification From Quality Module
Bring item specification records into PCO for modification
Select from current sequence of steps for a given parent item and routing
Once records are copied, use PCR/PCO Detail Maintenance - Item Specification to modify
Start with a copy of existing routing to simplify editing
PCR/PCO Detail Maintenance - Item Specification
Add test steps
Deactivate test steps
Sets an end effective date when PCO is incorporated
Modify existing test steps
Exercise: Create a PCO with Item Spec Changes
Engineering has found that the test procedure for 12-101 is not strict enough.
1 Use PCO Maintenance (1.9.2.13) to modify the Quality Management specifications to make the inspection use stricter standards.
Let QAD SE assign the PCO number.
 
Field
Data
Assign Type
PCO
Design Group
DESIGN
Write down the PCO number assigned for later reference: ____________________
2 Title and Reason fields are optional. Leave them blank, or create a simple description for this PCO:
 
Field
Data
Title
Test Spec
Reason
Modifying Item Specs for 12-101
3 Continue past the header. Choose Item Specification Maintenance. From this menu select Copy Item Specification from Quality Module.
a Item Number = 12-101; Routing Code = 12-101
b Click in the number field (an asterisk should appear next to the sequence). click Next to continue.
4 Click Back and choose Item Specification Maintenance, then PCR/PCO Detail Maintenance - Item Specification. Tab down to modify each of the records copied in the last step.
a For Test Sequence 1, Voltage, change the specifications to a range of 9.4<= Voltage =<9.6.
5 Save the record without adding any information to the trailer. Click Next, Back and Back.
6 Use PCR/PCO Detail Inquiry (1.9.2.8) to review your PCO and verify that your changes were all included.
Formula File Maintenance
Use Enable PCC Formula Maintenance (15.22) to access formula options
Use Formula File Maintenance to
Copy processes to the PCO
Copy where used
Maintain process records with Detail Maintenance
Replace components in multiple bills
Copy Formula into PCO
Specify Parent Item
Displays current bill of material
You select records to copy into PCO
Modify any selected records with PCR/PCO Detail Maintenance - Formulas
Copy Where Used into PCO
Works the same as Copy Formula into PCO except
Displays bill of material as indented where-used bill of material
Useful to make the same change to several formulas
PCR/PCO Detail Maintenance - Formulas
Add items to formulas
Delete formula records
Sets end effective date when PCO is incorporated
Edit formula changes
Replace Formula Component
Replace one component with another across multiple bills of material
Searches formula records already included in the PCO and marks the formulas as deactivated
Adds new formulas with the new component in place of the old component
Modified quantities are multiplied against the Multiplier value
Other detailed formula data is copied from the existing record
Exercise: Create a PCO with Formula Changes (optional)
Koolaire (TM) Coolant Standard, Scented (90-100) needs to have the perfume reduced in the formula because the supplier has started making the perfume in stronger concentration.
1 Use Formula Maintenance (15.5) to delete the existing formula for (Parent) 90-100, (Component) 90-2000.
a Rebuild the formula with Quantity Type P, and Batch Percent 10.
2 Use Formula Maintenance (15.5) to delete the existing formula for (Parent) 90-100, (Component) 90-4000.
b Rebuild the formula with Quantity per Batch <blank>, Quantity Type P, Batch Percent 75.
3 Use PCO Maintenance (1.9.2.13) to create a PCO to indicate the reduction of one component and the increase of other components by percentage.
Let QAD SE assign the PCO number.
 
Field
Data
Assign Type
PCO
Design Group
DESIGN
Write down the PCO number assigned for later reference: ____________________
4 Title and Reason fields are optional. Leave them blank, or create a simple description for this PCO:
 
Field
Data
Title
Formula Change
Reason
Modifying 90-100 to use less 90-2000 Concentration strength from supplier increased.
5 Continue past the header. Choose Formula File Maintenance. From this menu select Copy Formula into PCO.
a Parent Item = 90-100.
b Select components 90-2000 and 90-4000 (an asterisk should appear next to each sequence).
6 Choose Formula Data Maintenance, then PCR/PCO Detail Maintenance - Formulas. Arrow down to access both records copied in the previous step.
a For 90-2000, change the Batch Percent from 10 to 8. click Next. The Quantity Per changes automatically.
b For 90-4000, change the Batch Percent from 75 to 77. Click Next. The Quantity Per changes automatically.
7 Save the record without adding any information to the trailer.
8 Use PCR/PCO Detail Inquiry (1.9.2.8) to review your PCO and verify that your changes were all included.
Copy Processes to PCR/PCO
Copy processes
Modify existing processes with Detail Maintenance
Note: Routings cannot be maintained with this function
Use Routing File Maintenance for routing processes
Copy Processes to PCR/PCO
Copy process records to PCO for modification
Displays operations and lets you select which steps to include
Once the records are copied, use PCR/PCO Detail Maintenance - Processes to modify
Start with a copy of existing processes to simplify editing
PCR/PCO Detail Maintenance - Processes
Add operations to a process
Deactivate operation steps
Sets an end effective date when PCO is incorporated
Edit process changes
Exercise: Create a PCO with Process Changes (optional)
1 The pencil molding process has a scrap factor that has never been figured into the process. Select the process operation for the pencil, 04-0005, and use PCO Maintenance (1.9.2.13) to create a PCO for a yield of only 98%.
Let QAD SE assign the PCO number.
 
Field
Data
Assign Type
PCO
Design Group
DESIGN
Write down the PCO number assigned for later reference: ____________________
2 Title and Reason fields are optional. Leave them blank, or create a simple description for this PCO:
 
Field
Data
Title
Process Change
Reason
Modifying 04-0005 to change yield scrap factor of 2%
3 Continue past the header. Choose Process Data Maintenance, then Copy Processes to PCR/PCO.
a Routing Code = 04-0005.
b Select process 10 (an asterisk should appear next to the process).
4 Return and choose Process File Maintenance, then PCR/PCO Detail Maintenance - Processes. Arrow down to modify the record copies in the previous step.
a For 04-0005 operation 10, change the Yield Percent to 98%.
5 Save the record without adding any information to the trailer.
6 Use PCR/PCO Detail Inquiry (1.9.2.8) to review your PCO and verify that your changes were all included.
Enter Trailer
Trailer Maintenance (1.9.25.9)
Can be used to close or reopen a PCO (before it is distributed)
Displays information for the release process:
Routing slip
Distribution group
Date submitted
Date approved
The only option that appears in the PCO maintenance section menu for closed, but undistributed, PCOs
Trailer Maintenance
Closed = Yes closes the PCO
A PCO cannot be reopened after it is distributed
Disposition is an optional user-defined code for describing arrangement, grouping, and urgency of PCO
Generalized codes validated against ecm_ecr_dspn
Mandatory is optional, indicating the latest day by which the PCO must be implemented
Review/Print PCO
PCR/PCO Detail Inquiry (1.9.2.8)
Prints similar to Print PCR/PCO (1.9.9.1) but designed for just a single inquiry.
PCR/PCO Status Browse (1.9.11)
Status shown as a column in the browse
Blank status is Pre-submission
Print PCR/PCO (1.9.9.1)
Provides a complete printout of all PCO/PCR information for ranges of PCOs/PCRs
Prints header and status information, then (as appropriate) the approval group detail, item master detail, BOM detail in indented format, routing, process, and formula information, item specification data, and all text comments
Bill of materials section of the report prints only the PCO bill and includes the current Qty Per from the product structure or formula record and the PCO Qty Per
If a component has been deactivated, DEACTIVATED prints in the PCO Qty Per column
Exercise: Check Status and Print PCOs
In each of the exercises above you reviewed individual PCOs with a Detail Inquiry.
1 In this exercise, use PCR/PCO Status Browse (1.9.11) to review the status of all the PCOs created in the exercises above.
2 Use Print PCR/PCO (1.9.9.1) to print the PCOs you created. Leave the PCO Number field blank and enter the following:
 
Field
Data
Pre-submission
Yes
All other status fields
No
PCO/PCR
PCO
Output device
PAGE
Route PCO for Approval
Send the PCO to members of the Approval group for their consideration, approval, comment, rejection, or reapproval
Once the PCO has been routed, QAD SE restricts any changes to the document to ensure that the approved version is the most current version
Route PCO for Approval (1.9.2.16)
Lists PCOs in order, beginning with the PCO you enter in the first frame
Unsubmit Only = Yes selects all PCOs that have not been routed for approval yet
When you select a PCO for submittal in the top frame, it copies to the bottom frame
Submit = Yes submits the PCO for approval
Exercise: Route PCOs for Approval
Submit your first three PCOs to start the routing and approval process, using Route PCO for Approval (1.9.2.16).
1 Select the first three PCOs you created in these exercises (refer to the PCO numbers you recorded). Leave the number field blank and leave Unsubmit Only = Yes. This will filter for just the unsubmitted PCOs.
a Select a PCO in the first frame and click Next.
b When it appears in the second frame, verify Sbmt = Yes. Click Next to submit.
2 Use PCR/PCO Status Browse (1.9.11) to review your PCOs to verify that their status changed. You should see:
 
Three records with Status
Submit
The remaining PCOs with Status
<blank>
PCR/PCO Approval
Assign approval, rejection, or reapproval
Severity levels must be used to allow approval groups to reroute PCOs for reapproval
When the PCO has been routed, the recipients enter their approval, comments, rejection, or reapproval
PCR/PCO Approval (1.9.6.1)
When Unsigned Only = Yes, only pending approvals display (use = No to change prior approval)
Select PCO for approval in top frame
Set Appr = Yes in lower frame to approve
If disapproved and routing slip allow for rerouting, a prompt display asks for the reroute level
Detail Approval Maintenance (1.9.6.13)
Allows override of the normal approval process
Disapproved documents will not be rerouted
Important: Should be password controlled since it provides administrative override of normal approval process.
Approval Browse (1.9.6.2)
Browse the approval status of various PCRs/PCOs
Very similar to PCR/PCO Status Browse (1.9.11)
Release and Distribute PCO
When the approval process is complete and there are no more rerouting steps for reapproval, the PCO moves to Release and Distribution.
Release signals a change in ownership
Distribution is based on the routing slip
Release is final and irrevocable once it is distributed
Release and Distribution (1.9.7.1)
Select PCOs in the first frame, scroll through second frame, and select a PCO for release/distribution
Set Rels = Yes and enter a valid Batch ID or leave blank
Once you enter a Batch ID, the PCO is released; the PCO is distributed when the specified batch is executed
If Batch ID is left blank, then the PCO is released and distributed immediately
Released PCOs can be unreleased if they have not been distributed
Run Release and Distribution with Unreleased Only = No, select the PCO, and then set Rels = No
Distributed PCOs cannot be unreleased or modified
When a PCO is released and/or distributed, its status changes and the dates of release and distribution are recorded
When the PCO is distributed, it is printed for all members of the distribution group and becomes visible to Incorporation Selection (1.9.7.4)
Exercise: Approve PCOs
Approve your first three PCOs, using PCR/PCO Approval (1.9.6.1).
1 Select the first three PCOs you created in these exercises (refer to the PCO numbers you recorded). Leave the number field blank and leave Unsigned Only = Yes.
Note: Be sure to enter your login as User ID.
This will filter for just the unsubmitted PCOs. Ensure the Document Type is set to PCO.
a Select a PCO in the first frame and click Next.
b When it appears in the second frame, verify Appr = Yes. Click Next to submit. Continue until all are approved.
2 Use PCR/PCO Status Browse (1.9.11) to review your PCOs to verify that their status changed from Submitted to Approved.
Incorporate PCO
Incorporation specifies an effective date for PCO changes to move into the production files
Makes the changes available for planning
Moves the changes in the PCO that affect product structures, formulas, processes, routings, and item specifications into the planning files once there is an effectivity date
Makes data available to MRP, DRP, and other pre-production QAD SE modules
Until implemented, a PCO incorporation date can be changed and re-incorporated
Note: Incorporation of different revisions of the same parent item must be done in revision sequence.
Incorporation Selection (1.9.7.4)
Displays released and distributed PCOs, beginning with PCO specified in Number
Unincorporated Only allows you to filter display to pending PCOs
If two PCOs change data for the same item, they must be incorporated in revision level sequence
Select PCOs for incorporation and specify incorporation date
Incorporation does not happen until Incorporation (1.9.7.5) is run
Incorporation (1.9.7.5)
Updates the production database with all unincorporated PCOs that have effectivity dates
Normally run as a batch process
Incorporation Planning Report (1.9.7.3)
Incorporation makes PCO information available to planning
Use this optional report to evaluate the effects of the PCO on inventory
Exercise: Release and Distribute PCO
Use Release and Distribution (1.9.7.1) to release and distribute your first PCO. Incorporate these changes into QAD SE for planning consideration.
1 Select your first PCO for release.
a Leave the Number field blank.
b Type = PCO
c Unreleased Only = Yes
2 Then select the first PCO in the top frame to copy to the bottom frame. Verify Rels = Yes and click Next to release (leave Batch ID blank). You should see a message that the PCO was distributed successfully.
3 Use PCR/PCO Status Browse (1.9.11) to review your PCOs and verify the PCO that was released and distributed. You should now see Status = Released for your first PCO.
Exercise: Incorporate PCO
4 Use Incorporation Selection (1.9.7.4) to select your released PCO for incorporation. Leave the Number field blank, Type = PCO, and Unincorporated Only = Yes.
a Select the PCO in the first frame to bring it into the bottom frame. Assign the Eff Date = today.
5 Use Incorporation (1.9.7.5) to incorporate all PCOs with effective dates for today.
6 Use PCR/PCO Status Browse (1.9.11) to review your PCOs and verify the latest status change. You should now see Status = Incorp for your first PCO.
Implementation
Copies changes to item data records from incorporated PCOs when effective dates are reached.
Dependent on the effectivity date of the Incorporated PCOs
Usually run as a daily batch
Implementation (1.9.7.13)
Begin Implementation = Yes, and then specify an output device
Typically this function is run automatically every day
Can specify a Batch ID to execute daily
Exercise: Implement PCOs
Use PCR/PCO Approval (1.9.7.1) to implement the PCOs incorporated in the last exercise.
1 Leave the number field blank, select DocType = PCO, and review Unsigned Only = Yes. Select just the first two PCOs submitted. Mark each APPROVED.
2 Use PCR/PCO Status Browse (1.9.11) to review your PCOs and verify that their status changed. You should see:
 
Two PCOs with Status
Approval
One PCO with Status
Submit
The remaining PCOs with Status
Unsubmit
Use PCR/PCO Status Browse to verify the status.
Summary
Miscellaneous PCR/PCO Functions
PCR/PCO Import/Export (1.9.13)
Export PCO data to an ASCII text file
Import to restore archive files
PCR/PCO Delete/Archive (1.9.15)
Archive or delete closed records from the database
Course Overview
Exercise: Create a PCO with Process Changes (optional)
The plastic bottle molding process has a scrap factor that has never been figured into the process. Select the process operation for the mechanical pencil, 04-0005, and use PCO Maintenance (1.9.2.13) to create a PCO for a yield of only 98%.
1 Let QAD SE assign the PCO number.
 
Field
Data
Assign Type
PCO
Design Group
DESIGN
Exercise: Implement PCO
Use Implementation (1.9.7.13) to implement your incorporated PCO fully into QAD SE.
1 Run the implementation process.
2 Use PCR/PCO Status Browse (1.9.11) to review your PCOs to verify the latest status change. You should now see Status = Closed for your first PCO since it has completed the full processing cycle: Created/Routed/Approved/ Distributed/Incorporated/Implemented (Closed).