OVERVIEW

The Process Route Maintenance window is used in conjunction with the Process Routes Menu.

Within an MRP environment all manufactured assemblies should have process routes unless they are Phantom or Outwork type assemblies.

In this window you can set up the processes it takes to make up a parent part. This window has three tabs.

File Path

Masters > Process Routes > Select Assembly…

This file path takes you to the Process Route Maintenance window with the part selection window also open.

To set up a Process Route

To create a route, select the part number in the Part Selection window and click ok.

Details Tab

Right click in a blue area and select Add Operation. This will enter a new line for you to add a process to the parent part number.

The first operation number auto fills as 10 and all subsequent new process numbers are in increments of ten this is so you can add intermediate operations at a later date.

In the Work Centre field, select the show button and choose which work centre you want to add. Click here for our Work Centre guide.

Set the Set, Run and Lag times for this process.

If you are using the parts mass field to calculate product weight, you may need to account for any mass change (loss or gain) in the Change to mass field.

Texts Tab

In the texts tab you can enter any operational instructions you would like to include for this parent part. This text will show on a work order in the process route information for the operation number in question.

If you have set up your standard works text, you can select the show button and choose the appropriate code for the text you would like to enter. This text will show on a work order in the process route information for the operation number in question, this can be in addition to the operational instructions.

Extra Tab

Here you can enter any extra scheduler text which is used for transfer to finite scheduler software.

BUTTONS AND FIELDS

Main Window

Parent Part Number

This field shows the parent part number currently in use.

Parent Description

The parent part number description is shown here.

Parent Stock Units

This is the parent parts standard stock unit of measure.

Parent Re-Order Quantity

The standard re-order quantity for this parent part is displayed here.

Assembly Tree

The parent part number is displayed in the left-hand field. You can expand the parent part number to show the sub-assemblies by clicking on the arrow next to the part number. Each sub assembly could have its own process route.

Operations List

In this field you can see the process routes that make up the selected parent part.

The legend at the bottom of the window details the icons.

Batch Set Hours

The total set hours for all operations for any batch size are shown here. Outwork operations are ignored.

Batch Run Hours

Total runtime hours for all operations, assuming minimum order qty batch size. Out work operations are ignored.

Batch Lag Hours

Total lag hours for all operations for any batch size.

Unit Cost

This field shows the parent unit value of operational costs based on times and work centre rates.

Where-used Icon button

This icon is next to the Assembly Tree title and if selected, loads the higher parents of the selected part, if there are any and they are not already listed.

Clear Tree List button

This icon is next to the Assembly Tree title and if selected, clears all assemblies from the tree.

Revert button

If selected, all changes will be lost except deletes.

Save Changes button

Saves all component changes and additions to file. Consequential adjustments will also be made.

Cancel button

This will cancel the process currently in session.

OK button

Selecting this will update the data you have entered or confirms the selection and/or processes the function you have called.

Details Tab

Operation Number

The sequence number 1-999 are used for the individual operations. The system standard uses multiples of 10 to allow for additional intermediate operations at a later date.

WARNING – The system permits the change of an operation number. Works History records manufacturing performance by operation number. Changing the Operation number in the Process route will not change the Work history records. Work Order Operations is a list of operations for a specific Work Order, Operations Numbers in this list are not affected by changes to the Process Route.

Alternative (tick box)

Select if operation is an alternative, not costed and not forward planned.

Tip – Alternative Operations are those that are not included in normal route functions such as costing, planning and mass calculations. They are available for Work Orders and can form part of the manufacturing process, including outwork operations. However, when they have the same operation number as a non-alternate operation one of them must be selected before a Work Order can be created. See Work Order Maintenance for more details of how you can operate flexible routings.

Work Centre Code

Here you can enter the required work centre code. You can also choose your work centre from the pre-defined list by clicking the show button and double clicking on the work centre line you want to apply to the operation.

Click here for our Work Centre Maintenance guide.

Work Centre List

When the show button is selected a list of all available work centres is shown. Double click to select a work centre.

Set Time

This is the total amount of time to prepare the work centre for a production run.

Run Time

This is the time in hours to carry out this operation on each Stock UoM of the Parent part, having setup the Work centre.

Lag Time

This is the lag time in hours.

The delay time provision in hours that is maximum for this operation. For normal Work Centres, it can be either positive or negative. For outwork Work Centres it can only be positive. It’s absolute value must be less than 10,000 to 2 decimal places. This figure is used in Capacity planning to schedule the work centre loading. It does not affect product costing.

When the Lag time is zero or positive, the setup for the following operation will be scheduled to start the number of Lag hours after the end of the run processing. If the Lag time is negative, the run time of the following operation will be scheduled to start the absolute number of Lag hours after the start of the run time of this operation.

Positive Lag time will include transit time between work centres and other delays such as queuing or drying/cooling, etc.. Negative Lag time, is the time after starting run processing of one operation before the following operation run processing can start. The extent of scheduled operations based on their work centre’s hours per day may be equal to the parent part’s lead time if there are no restrictions to capacity. The default lag time is that provided from the work centre record. Using Lag time has a profound effect on Global Changes Lead Time calculations for the assembly.

If you leave a negative Lag Time on the last operation of a route, scheduling will be calculated using zero.

TIP: If you set an operation’s Lag time at -0.01, the following operation will, in effect, run in parallel to it. However, if the run duration of the first operation is greater than the run duration of the following one, sequencing will fix the two run completion times to be the same.

NOTE: In capacity planning operations of outwork work centres are scheduled on the positive Lag Time only. Such operations use setup and runtime for costing purposes only. Lag time enables you to correctly schedule for outwork processing duration between normal in-house work centre operations within the route.

TIP: Make the outwork work centres 1 hour per day and then you can use the Lag Hours field to represent the number of days the outwork operation will take to process.

Change to Mass

If you are using the parts mass field to calculate product weight, you may need to account for mass change during an operation. You should account here for any loss (-ve) or gain in mass during the course of the operation processing with respect to the sum of the masses of the BoM components.

Texts Tab

Operation Instructions

Operation instructions text can be entered here.

Standard Works Text Code

The standard works text code is shown here.

Show button

Clicking this button will display a list of alternatives for the standard works text code. Double-clicking on a list line will enter the value from the list.

Standard Text List

A list of all works standard texts contained in the standard text library. Double click on a line to select and enter it.

Standard Works Text

This is the standard text that will be entered.

Extra Tab

Extra Scheduler text

Extra information for the scheduler can be entered here.

Mass Change button

To mass change the extra txt, selectively by part and work centre ranges. This opens the Process Route Extra Text Mass Change window.

Compiled in Program Version 6.00.

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OVERVIEW

To set up capacity planning you must first set up your process routes. Process operations make up process routes and there should be one process route for each non-phantom assembly. A single end part may have several process routes as it makes its way through as many different work centres as required.

File Path

Masters > Process Routes > Work Centres

This file path will take you to the Work Centre Maintenance window.

Add button

Selecting this button will allow you to set up a new work centre and will highlight the next available line in the work centre field at the top of the screen.

Work Centre

Insert the name of the work centre here. This can be up to three characters in length eg. WST or QTY.

Description

Enter the name of the workstation in this field eg. Workstation or Quality Control.

Quantity of Centres

The amount of this type of work centre goes here. Eg. You may have 3 Workstations but only one Quality Control area available.

Available time

How much available time is allocated per day to each workstation.

TIP: Having 2 work centres, each with 8 hours per day, is not the same as having 1 work centre working 16 hours a day. A Work Order batch can only pass through one Work Centre. An 8-hour operation will take a full day in the first case whereas it will take a half day in the latter case. In this way you can identify work centres that can operate operations in parallel or series.

Department Code

You may have several work centres allocated to the same department code eg. Workstation and paint may all come under assembly, and you may want to use the code ASSY.

Outwork Work Centre

Tick this box if this is an outwork work centre.

Setup Labour

Enter the setup labour rate per hour for the workstation here.

Setup Overhead

Enter the setup overhead rate per hour in this field.

Runtime Labour

The runtime labour rate is entered here.

Runtime Overhead

The runtime overhead hourly rate is entered here.

Operation defaults

Lag

The lag time in hours is entered here.

Setup

The setup time in hours is entered in this field.

Commission Class

The commission class for this workstation can be entered in this box as appropriate.

Default Margin

The default commission margin is entered here.

BUTTONS AND FIELDS

Work Centre List

In this field you will see a list of all your work centres. To amend work centre details, highlight the appropriate line on this list. The data for this Work Centre can now be changed.

Work Centre Code

This is your unique identifier code for your work centre.

Description

This is the description of your work centre.

Available Time

Hours available in each Make Day for the work centre.

Department Code

This is used to group work centres. You can use this as a way to group departments and view capacity analysis by department rather than specific work centres.

Outwork Work Centre

This box would be ticked if you wish this work centre to be designated as an outwork centre.

If you designate a Work Centre as an Outwork work centre, operations assigned to it are assumed to be processed by an outside sub-contractor. These operations must be purchased on a Purchase Order and then received in the normal PO manner before further normal operations can be processed.

NOTE – Care should be taken with applying cost rates to Outwork work centres. It is recommended that you apply a single unit of cost (1.00, or 10.00 or 100.00) to both setup and run labour rates, with zero overhead rates. Then use setup and run times to determine costs.

Setup Labour Rate

This is the set-up labour cost per hour.

Setup Overhead Rate

In this field you can enter the setup overhead cost per hour. This should include normal overheads attributable to the Work Centre as well as any special set-up consumables not provided for in the Bill of Materials.

Runtime Labour Rate

This is the runtime labour rate per hour for the selected workstation eg. If you have 2 people working at that station each on £10 per hour, the runtime labour rate per hour will be £20.

Runtime Overhead Rate

The runtime overhead cost per hour is entered here. This should include normal overheads attributable to the Work Centre as well as any special time based consumables not provided for in the Bill of Materials.

Default Operation Lag Time

The default operation lag time for process route maintenance is entered in this box.

Default Operation Setup Time

You can enter any default operation setup time for process route maintenance here.

Job Operation Commission Class

Enter any appropriate commission class previously set up in the Commissioned Sales Agents Maintenance window.

WARNING: If a blank commission class is applied, no commission agents will be filtered onto job lines.

Default Margin

Enter the default margin to be applied to job operations for the commission class.

Add Button

Selecting this button will create a new (normally blank) record in the file ready for you to enter details for the record.

Delete Button

If you select this button, you will permanently remove the currently selected record from the file. You will be asked to confirm you wish to delete the highlighted work centre. You can confirm with a yes or abandon the deletion with a no.

Mass Change Button

To mass change one work centre for another for a range of parts. This is particularly useful when you want to delete an obsolete work centre. It opens the Work Centre Mass Change window.

Print List Button

This button will cause a report to be printed of the subject matter.

Revert to Saved Button

This will cancel any changes and revert to the last saved record.

Save Changes Button

Selecting this button will save any changes you have made.

Compiled in Program Version 6.00. Help date last modified on 7 July 2021

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Parent Lead Time Adjustment

Reference Contents > Process Routes > Parent Lead Time Adjustment

This window is opened then you operate the Masters — Process Routes — Parent Lead Time function having selected a parent in the Process Route Maintenance window. You can change the parent part lead time to the sum of the process route operations times (rounded up to the nearest working day).

The operation times are calculated into days by using the respective work centre available hours per day. This provides for quick adjustment of parent part lead time which is used in MRP processing. There is also a Global Change function that can be used to auto-calculate lead times for a range of parent parts (see the Parts Global Lead Time Auto-Calculate window topic for details).

Button	Action
Cancel	Aborts the process currently in session. The keyboard equivalent is the Esc key for Windows computers and Command-.(full stop or period) for the Mac.
OK	The OK button updates the data you have entered, or confirms the selection and/or processes the function you have called.

See also: –

– Process Routes Menu Process Route Maintenance

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Process Route Maintenance

Reference Contents > Process Routes > Process Route Maintenance

The Process Route Maintenance window is used in conjunction with the Process Routes Menu.

It contains an assembly tree list that can be populated using drag and drop from the parts ScratchPad or directly by using the Select Parent function on the Route menu. When an assembly number is selected in the tree list the parent’s operations list is built and displayed.

To create a route, select the part number or drag it into the assembly list and select it. Then add operations to the list.

The operation list has columns for Operation number, Work centre, Operation instructions, Standard engineering text code, Set time hours, Run time and Lag time hours and set and run costs. At the bottom of the list the calculated parent lead time and time and cost totals for the entire process route are provided. Alternative Operations are not included in the totals.

Button	Action
Where-used Icon button	Loads the higher parents of the selected part, if there are any and they are not already listed.
Clear Tree List button	Clears all assembles from the tree.
Revert	Re-reads the modified Bom from file. All changes other than deletes will be lost.
Save Changes	Saves all component changes and additions to file. Consequential adjustments will also be made.
Cancel	Aborts the process currently in session. The keyboard equivalent is the Esc key for Windows computers and Command-.(full stop or period) for the Mac.
OK	The OK button updates the data you have entered, or confirms the selection and/or processes the function you have called.

The window has 3 tab panes.

Details 
Texts 
Extra 

Details

TIP: You can use the optWOHistoryEditPlan option in Settings Maintenance at any level to permit the editing of planned hours in the Log Work Order Performance window. This is useful if you have route operations that are alternates. Typically, if this were the case one operation would have valid hours (the default) and the other would have zero hours set in the route (the alternative). When you use the alternative operation, you need to zero the work history planned hours otherwise these will contribute to the cost of the WO (this is because where no actual hours are set for an operation, the planned hours are costed).

Entering Time Values using HMSP Syntax

The system stores and uses times in decimal hours. 1.5000 hours rather than 1hr 30min. However, you can enter time in a number of different ways that will automatically convert to the equivalent decimal hours when you leave the field.

Back to top

Texts

Use this pane to view the operation texts.

Back to top

Extra

Operation extra text for transfer to finite scheduler software.

Button	Action
Mass Change	To mass change the extra text, selectively by part and work centre ranges. It opens the Process Route Extra Text Mass Change window

Back to top

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Process Times Update

Reference Contents > Process Routes > Process Times Update

This function calculates optionally set and run times for assembly route operations from work history. It applies to all operations for an assembly part. It is particularly useful for assemblies made for the first time where times are initially not known and shopfloor times are being recorded.

First choose from the checkbox option what you wish to update. Then select the assembly parts you want to apply the update to in the Parts ScratchPad. Drag these selected lines and drop them on the window.

An Alert Message will warn you of any anomalies encountered such as missing history for an operation.

Field	Description
Update Set Time	Check to update set times.
Only If Zero	Check if the update is to apply only if the current value is zero.
Update Runtime	Check to update run times.
Only If Zero	Check if the update is to apply only if the current value is zero.
Update Lag Time to:	Check this option to update the operation lag times.
Lag Time	To apply a lag time to all operations, enter a lag value here.
Only If Zero	Check if the update is to apply only if the current value is zero.

Compiled in Program Version 5.10. Help data last modified 17 May 2012 02:10:00.00. Class wProOpTimes last modified 4 Aug 2015 16:38:27.

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Parent Minimum Order and Lot Size Adjustment

Reference Contents > Process Routes > Parent Minimum Order and Lot Size Adjustment

This window is opened then you operate the Masters — Process Routes — Parent Order Quantities function having selected a parent in the Process Route Maintenance window. You can change the parent part minimum order quantity and lot size and view parent costs for different parent re-order quantities.

Because of the operation setup times the overall cost of products can be significantly affected by the normal production batch quantity. This window enables you to review the affect of minimum order quantity on the route cost and part cost. You can enter any quantities to view the cost implication. Having changed the Minimum Order Quantity and/or Lot Size, clicking OK or pressing the enter key will re-set the part quantities in the parts master record.

NOTE: Part quantities will only be updated if you have “Update” privileges in the Parts maintenance menu. Otherwise two alerts will sound.

Button	Action
Cancel	Aborts the process currently in session. The keyboard equivalent is the Esc key for Windows computers and Command-.(full stop or period) for the Mac.
OK	The OK button updates the data you have entered, or confirms the selection and/or processes the function you have called.

See also: –

– Process Routes Menu Process Route Maintenance

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Process Route Reports

Reference Contents > Process Routes > Process Route Reports

This report setup window provides you with the ability to choose a range of selections, sort order and report types.

You can drag and drop onto the Print Report button from the Parts ScratchPads to obtain a report of selected parts only.

NOTE: This window contains fields introduced with version 5 that enable additional search (and sometimes sort controls), such as Adhoc extra where. For more help on their use and examples see the Client-Server SQL Introduction help.

Button	Action
Cancel	Aborts the process currently in session. The keyboard equivalent is the Esc key for Windows computers and Command-.(full stop or period) for the Mac.
Print Report	Will cause a report to be printed of the subject matter. Right-click to change the report destination.

See also: –

Process Route Operation Selection

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Process Route Operation Selection

Reference Contents > Process Routes > Process Route Operation Selection

This subwindow is used to define the range criteria for a selection of process route operations. It is displayed on windows requiring their selection.

Parent Windows

Process Route Reports
Process Route Extra Text Mass Change
Link System Maintenance
Graphical Analysis Maintenance – Graphs Tab

Operation

Enter data in the data entry boxes to restrict the range of parts. Records must meet all criteria entered to be selected. If the left and/or right data entry boxes are left blank for a particular criteria, record will be selected between the first and/or last otherwise qualifying record. Data entry boxes can be populated by finding a single item using Keyword Search, drag and drop from the Parts ScratchPad, or by double-clicking a list item from the Keyword Result window.

Data records can be obtained using one of the following methods or a combination of them (see Tip below):

1. Enter values into the selection ranges and use the Standard Search. The context menu provides a Clear Selection function.
2. Define or use a Custom Search.
3. Create an Ad Hoc Search Calculation using the context menu function.
4. Drag-and-drop one or more lines from the Parts ScratchPad (or BoM and Where-Used Listing) onto the general window area.
5. Use the ScratchPad Transfer Selected function
6. Use the KeyWord Search Transfer Selected function

TIP: Using an Ad Hoc Search Calculation (3) overrides any Custom Search (2) and a Custom Search overrides the Standard Search (1). In any of the search cases (1, 2 or 3), ScratchPad Transfer and Drag-and-Drop or KeyWord Search Transfer (4, 5 or 6) is combinational, so that records found using any of these methods must also conform to the search criteria adopted.

NOTE: This window contains fields introduced with version 5 that enable additional search (and sometimes sort controls), such as Adhoc extra where. For more help on their use and examples see the Client-Server SQL Introduction help.

Button	Action
Custom Search	Opens the Custom Search Selection window and checks the Use custom checkbox.

See also: –

Search Options Menu Process Route Reports Process Route Extra Text Mass Change Parts ScratchPad Keyword Result

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Work Centre Mass Change

Reference Contents > Process Routes > Work Centre Mass Change

This window is opened then you operate the Mass Change button on the Work Centre Maintenance window.

It allows you to change the use of a Work Centre on Process Routes and also optionally in Works History. It is to provide for re-organisation of the Work Centres.

You must enter a Work Centre that will replace the selected one on all process routes/work history for the range of parts entered.

WARNING: Take great care. This is not a reversible process and could lead to considerable problems if used inappropriately.

TIP: If you want to delete a Work Centre which has history you cannot remove, set up a dummy ‘obsolete’ work centre and transfer the work history into that before deleting the original work centre.

Button	Action
Process Change	Process the conversion of one work centre for another.

See also: –

Work Centre Maintenance

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Work Centre Maintenance

Reference Contents > Process Routes > Work Centre Maintenance

This window is opened then you operate the Masters — Process Routes — Work Centres function. Within it you can carry out all maintenance functions for Work Centres.

Work Centres for the production processing must be defined so that the location of process route operations can be identified. Process operations make up process routes and there should be one process route for each non-phantom assembly. The Process operations define the expected time an operation will take in the manufacturing of the assembly. The Work Centre defines the location of that processing and the cost rates for the particular type of processing carried out at that location. Work Centres can be machine tools, assembly areas, process equipment, etc. Changes in work centre cost rates will have an immediate effect on list and report valuations of process route costs, but will only have an effect on part current costs after a product cost roll-up.

Button	Action
Add	This will create a new (normally blank) record in the file. You will then be able to enter details for the record. Then confirm with an OK, or abandon the New record with a Cancel.
Delete	Execute this button to permanently remove the currently selected record from the file. If you are permitted to delete the item, you will be asked for confirmation, otherwise an explanation will be given.
Mass Change…	To mass change one work centre for another for a range of parts. This is particularly useful when you want to delete an obsolete work centre. It opens the Work Centre Mass Change window.
Print List	Will cause a report to be printed of the subject matter. Right-click to change the report destination.
Revert to Saved	To cancel any changes and revert to that last saved.
Save Changes	To save any changes you have made.

See also: –

Work Centre Mass Change

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