Maintenance and Manufacturing Interface—Exercises

Basic Data Setup 

Enter and Link Employee to Maintenance Organization

Purpose: The purpose of this exercise is to show you how to enter and link an employee and to connect this employee to a certain maintenance organization. This basic data is required for the Work Processing course.

Windows:
Organization Basic Data /Employees

  1. Enter a new employee.
  2. Link a maintenance organization to the employee.

General exercise for Enter and Link Employee to Maintenance Organization

Operational Status

Purpose: The purpose of this exercise is to show you how to set up the operational status that is required for the Work Processing course.

Windows:
Work Order and PM Basic Data /Operational Status

  1. Enter a new operational status as the Not Obstructive operational status type.

General exercise for Operational Status

Work Center

Purpose: The purpose of this exercise is to show you how to create a work center so that work order information can be seen in IFS Manufacturing as a work order load, and so that IFS Maintenance can see shop order load on a work center.

Windows:
Work Center

  1. Open the Work Center window, and create a new work center (F5).
  2. Enter a work center ID and description, e.g., WC1 - Work Center 1. 

Note: The work center ID can be different from the object ID that you entered above.

  1. Save the new information (F12).
  2. Click the Resource tab.
  3. Connect the work center resource to the object that you entered above by entering the object ID in the Object ID field. You can also select a value from the List of Values (F8).
  4. Save the new information (F12).

Required Data

Functional Object

Purpose: The purpose of this exercise is to show you how to create an equipment object to be used as a manufacturing work center.

Windows:
Functional Object

  1. Open the Functional Object window.
  2. Create a new functional object (F5). 
  3. Define an object ID and object description. The description should indicate that this equipment object is a manufacturing work center, e.g., WC1 - Work Center 1.
  4. Save the new functional object (F12).

Note: The object could just as well be a serial object. The object can also be part of a structure.

General exercise for Object Structure

Manufacturing Part

Purpose: The purpose of this exercise is to show you how to create a manufacturing part being manufactured on a shop order.

Windows:
Inventory Part

You are now going to create a simple manufacturing part that you will later manufacture on a shop order. The part you are going to manufacture will consist of only one component, and for this purpose, you need to enter one parent part and one component part.

  1. Open the Inventory Part window.
  2. Create a new inventory part (F5). This should be your parent part (the part that you will make). Enter a part number and part description, e.g., MF1 - Manufactured Part 1.
  3. Select Manufactured as the part type.
  4. Select a planner using the List of Values (F8), e.g., * (asterisk).
  5. Select a unit of measure (U/M) using the List of Values, e.g., pcs.
  6. Save the new record.
  7. Click the Costs tab. Enter an estimated material cost, e.g., 10.
  8. Save the new record.
  9. Create another inventory part. This should be your manufacturing component. Enter a part number and part description, e.g., P1 - Purchased Part 1.
  10. In the Part Type list, click Purchased.
  11. Select a planner using the List of Values (F8), e.g., * (asterisk).
  12. Select a unit of measure (U/M) using the List of Values, e.g., pcs.
  13. Save the new record.
  14. Click the Costs tab. Enter an estimated material cost, e.g., 8.
  15. Save the new record (F12).

General exercise for Manufactured Inventory Part

Product Structure

Purpose: The purpose of this exercise is to show you how to create a product structure.

Windows:
Product Structure

  1. Open the Product Structure window.
  2. Query (F3) for your manufacturing part, MF1.
  3. On the Product Structure tab, create a new line (F5).
  4. Enter your purchase part number (P1) in the Component Part field.
  5. Enter 1 in the Qty Per Assembly field.
  6. Save the new record.
  7. Click the Product Structure tab, right-click, and then click Build.

Create Routings

Purpose: The purpose of this exercise is to show you how to create a routing.

Windows:
Routing

Note: To create a load on the work center, you must define an operation.

  1. Open the Routing window.
  2. Query (F3) for your manufacturing part, MF1.
  3. On the Routings tab, create a new line (F5).
  4. Enter 1 as the operation number and Inspect as the description.
  5. Select your work center (WC1) in the Work Center No field.
  6. Enter a number (1) in the Mach Run Factor field. This means that it will take one hour to perform the inspection operation.
  7. Save the new record.
  8. In the header portion of the Routings tab, right-click and then click Build.

Main Exercises

Purpose: The purpose of these exercises is to show you how to set up shop orders to view obstructive maintenance, and work orders to view manufacturing load.

Windows:
Shop Order
Prepare Work Order
Load per Work Center

Create Shop Order

Note: To create a load on a work center, you need to create a shop order.

  1. Open the Shop Order window.
  2. Create a new shop order (F5).
  3. Enter your manufacturing part ID (MF1) in the Part No field.
  4. Enter a lot size of 10.
  5. Save the new record.
  6. Click the Operation tab. One operation should appear, showing remaining manufacturing hours of 10. This is this shop order's load on the work center.

Create WO and View Manufacturing Load

  1. Open the Prepare Work Order window.
  2. Create a new work order (F5) for the work center object (WC1).
  3. Enter an optional directive.
  4. Enter appropriate start and finish dates. These dates should overlap completely or partially with the dates on the shop order.
  5. Optionally, select a maintenance organization using the List of Values (F8).
  6. Save the new work order.
  7. Click the Prepare tab. You should now be able to see a work center load.

Note: If you do not see a work center load on the work order, it could be that the dates on the work order and shop order do not overlap. You will be able to see a work center load only if a shop order exists for the same time as the work order is planned to be executed. You should also make sure that the object ID is connected to the work center resource and that the shop order operation uses the work center.

Create Obstructive WO

  1. Open the Prepare Work Order window.
  2. Create a new work order (F5) for the work center object (WC1).
  3. Optionally, enter a directive.
  4. Enter appropriate start and finish dates. These dates should overlap completely or partially with the dates on the shop order.
  5. Optionally, select a maintenance organization using the List of Values (F8).
  6. Save the new work order.
  7. Click the Prepare tab. Select an operational status that is Obstructive using the List of Values (F8).
  8. Save the new information.
  9. Refresh the work order (Shift+F5). You should now be able to see a work center load.
  10. Right-click, point to Work Order Status and then click Release.  
  11. If a shop order load exists during the planned execution time of the work order, a message appears indicating that you are about to release a work order that will have an impact on manufacturing. Click OK.

View Obstructive Maintenance Load on Work Center

Note: If there are obstructive work orders and shop orders planned for the same day, the obstructive maintenance load appears as a work center load.

  1. Open the Load per Work Center window.
  2. Query (F3) for your work center (WC1).
  3. Make sure the From and To dates includes the dates you have entered on your work order(s) and shop order(s). If you would like to see the load for other dates, enter new From and To dates, and refresh the graph (Shift+F5). You should now be able to see your shop order load and your obstructive maintenance load. The maintenance load appears as a gray staple. The colored staples show the shop order load.
  4. Either the shop order or the work order should be rescheduled, if possible, to ensure that the manufacturing process is not interrupted.

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