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Routing Operations

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Overview

Routing Operations describe the steps in routing. Each Routing Operation denotes a step in the production process.

Application

The Routing Operations program is used to view, edit, and delete Operations that have been established using the Routing Master. New Operations are established using the Routing Master. Routing Operations are used in the Work Order Extract Operations button to create Work Order Operations, representing the steps required to produce an item. Routing Operations are also used as a basis for computing the standard unit labor costs (and other associated overhead costs) for a manufactured item during the Generate / Apply Simulated Rollup Costs process. Work Orders use Routings and Operations for shop floor scheduling, as a means of tracking the progress of the Work Order (units completed through Operations) and the planned cost of the Work Order and to record the actual cost of Operations. 

Navigation

Rootstock Site Map > Shop Floor > Routing Master > Routing Operations Section

User-added image  NOTE  Assumes the user has already established a Routing Master record for the manufactured item.

In Routing Operations section, click either Add Standard Operation, Add Subcontract Operation, or Add Concurrent Operation button to create the corresponding type of Routing Operation.

Routing Operation Header

Information Section:

Fields
 

Division:  Displays the Manufacturing Division for this Operation. Display only, and comes from the Routing Master. Operations cannot span Manufacturing Divisions.

Site:  Select the Site for the Routing Operation.

Operation Type:  Identifies the type of Operation.
 

  • Standard Operation: Standard Operations typically must be done sequentially. With standard Operations, the user can report time against an Operation out of sequence, but the user cannot actually move materials (report quantities) out of sequence.

    • An option at the division level can be set to allow completions out of sequence. The field is labeled as ‘Allow Qty Comp Per Qty Req vs Qty Avail’, on the Shop Floor Control tab of the Division Master.

  • Subcontract Operation: A Subcontract Operation is an Operation provided by a Vendor. The part goes to the vendor and is returned by the vendor as the same item #.

  • Concurrent Operation: A Concurrent Operation is an operation that can be performed in parallel with another Operation(s), and does not need the previous Operation to be completed first. Quantities complete may be reported against any of the Concurrent Operations.


Concurrent Seq:  This field refers to a # (sequence) that defines a set of Concurrent Operations. The system automatically establishes this when concurrent Operations are added. This field is not used if the 'Operation Type' is not 'Concurrent Operation'.

  EXAMPLE  Operation 010 must be processed before Operation 020, which is processed concurrently with Operation 030, which must be processed before Operation 040. Setting the Concurrent Sequence to 1 for both Operations 020 and 030 would indicate that these two Operations represent the first set of Concurrent Operations from a scheduling perspective. If Operations 060 and 070 later on in the routing were Concurrent Operations together, both Operations 060 and 070 would get assigned a Concurrent Sequence of 2, indicating that these two Operations are the second set of concurrent Operations from a scheduling standpoint.

In a Concurrent Operation set, the operation with the highest Operation # must be completed in order for the order to proceed to the next Standard Operation. Scheduling is done using the greatest time of the Concurrent Operations.

Process Number:  This is a lookup to the Process Master table. Select the Process Master to be associated with this Operation.

Work Center:  The Work Center where this Operation will be performed. This is a Lookup to the Work Center Master.

Sim to Std Roll Date:  The date simulated cost was last rolled to standard cost. (System populated)

Header ID:  A system-generated entity. Displays the Routing Master for this Routing Operation.

Item Number:  Displays the Engineering Item Master # for this Operation.

Operation Number:  A user-defined Operation # (sequence) that identifies the step in the routing and the order in each step is performed. It must be a numeric value.

NOTE image.png  NOTE  It is suggested to use the numbering in increments of 10 to allow for future modification.

EXAMPLE image.png  EXAMPLE  Consider that a Routing Master needs to have five Operations. Then, create those five Operations with the 'Operation Number' as 10, 20, 30, 40, and 50. So, if a new Operation needs to be added between the first and second Operations, it can be created with the 'Operation Number' as 15.

Description:  The user-defined description for this Operation.

Outside Operation:  When checked, indicates that this Operation is performed by a Subcontract Vendor.

Labor Only Operation:  When checked, it indicates that this is a 'Labor Only' Operation.


Labor Stds Tab
 

Setup Time Type:  This signifies whether or not setup is required for this Operation.

  • None: Setup time is not required.

  • Per Batch: Setup time is a flat amount, regardless of order qty.

  • Per Piece: Setup time is required for each piece being produced.


Setup Grade:  Specifies the Labor Grade for the setup time and is used in rolling up the standard cost of the Operation.

Setup Std Option:  The method of updating the Setup Hours value.

  • Manual Entry: This setting indicates that the system will not copy the Setup Hours Simulated to Setup Hours Standard during the 'Set Standard from Simulated' cost update program and that the Setup Hours Standard will be maintained manually.

  • Copy from Simulated: This setting indicates that the system will copy the Setup Hours Simulated to Setup Hours Standard during the 'Set Standard from Simulated' cost update program. The ‘Setup Hours, Standard’ field is disabled under this setting.


Setup Hours, Simulated:  The Simulated Setup Hours for the Operation, manually maintained by the user. If the 'Setup Std Option' is set to 'Copy from Simulated', then this value is copied to the 'Setup Hours, Standard' during the Cost Rollup process, which is then used to calculate standards. If the 'Setup Std Option' is set to 'Manual Entry', this field is for reference only and is not copied to 'Setup Hours, Standard'. If 'Setup Time Type' is 'Per Batch' or 'Per Piece', this value must be greater than 0.

EXAMPLE image.png  EXAMPLE  For this Operation, consider that it takes 2 hours to set up all the components ('Setup Time Type' is 'Per Batch'), so set this 'Setup Hours, Simulated' to 2.

Setup Hours, Standard:  This is the value of Standard Setup Hours for the Operation, which is copied from the 'Setup Hours, Simulated' during the Cost Rollup process if the 'Setup Std Option' is set to 'Copy from Simulated'. Otherwise, this field has to be set manually by the user. The value in this field is then used to calculate standards. This value is also the Setup Time used in Work Order Operation Scheduling. If the 'Setup Time Type' is 'Per Batch' or 'Per Piece', this value must be greater than 0.

EXAMPLE image.png  EXAMPLE 

  • If the 'Setup Std Option' is set as 'Copy from Simulated', considering our example above, the 'Setup Hours, Standard' will be set to 2 during the cost rollup process.

  • If the 'Setup Std Option' is set as 'Manual Entry', then set this to a desired numerical value.


Run Time Type:  This field signifies whether or not Run Time is required for this Operation.

  • None:  Run Time is not required

  • Per Batch:  Run Time is a flat amount, regardless of order qty

  • Per Piece:  Run Time is the time required to do one part. This time is multiplied by the order qty to determine the full amount of time required for the Operation, in addition to any setup time, queue time, etc.


Run Grade:  This field specifies the Labor Grade for the Run Time and is used in rolling up the standard cost of the Operation.

Run Std Option:  The method of updating the Run Hours value.

  • None:  No run time is planned for this Operation.

  • Manual Entry:  This indicates that the system will not copy the Run Hours Simulated to Run Hours Standard during the 'Set Standard from Simulated' cost update program and that the Run Hours Standard will be maintained manually.

  • Copy from Simulated:  This setting indicates that the system will copy the Run Hours Simulated to Run Hours Standard during the 'Set Standard from Simulated' cost update program. When this value is set, the Run Hours, Standard field is disabled and is maintained by the Cost Rollup process.


Run Hours, Simulated:  This is the value of Simulated Run Hours for the Operation, which is manually maintained by the user. If the 'Run Std Option' is set to 'Copy from Simulated', then this value is copied to 'Run Hours, Standard' during the Cost Rollup process, which is then used in calculating standards. If the 'Run Std Option' is set to 'Manual Entry', then this field is for reference only and is not copied to 'Run Hours, Standard'. If 'Run Time Type' is 'Per Batch' or 'Per Piece', this value must be greater than 0.

EXAMPLE image.png  EXAMPLE  For this Operation, if the time it takes to process each component ('Run Time Type' is 'Per Piece') is 1 hour, then set this 'Run Hours, Simulated' as 1.

Run Hours, Standard:  This is the value of Standard Run Hours for the Operation, which is copied from the 'Run Hours, Simulated' during the Cost Rollup process if the 'Run Std Option' is set to 'Copy from Simulated'. Otherwise, this field has to be set manually by the user. The value in this field is then used to calculate standards. This value is also the Run Time used in the Work Order Operation Scheduling. If 'Run Time Type' is 'Per Batch' or 'Per Piece', this value must be greater than 0.

EXAMPLE image.png  EXAMPLE 

  • If the 'Run Std Option' is set as 'Copy from Simulated', considering our example above, the 'Run Hours, Standard' will be set to 1 during the cost rollup process.

  • If the 'Run Std Option' is set as 'Manual Entry', then set this to a desired numerical value.


Machine Stds Tab

Fields
 

Machine Type:  This field signifies whether or not Machine Time is generally required for this Operation.

  • None: Machine Time is not required.

  • Per Batch: Machine Time is a flat amount, regardless of order qty.

  • Per Piece: Machine Time is required, per piece.


Machine Number:  This is a lookup to the Machine Master and specifies the Machine required for this Operation. Required if either 'Batch' or 'Per Piece' is specified as the 'Machine Type'. Otherwise, this value must be 'None'.

Machine Std Option:  The method of updating the Setup Hrs value.

  • Manual Entry: This setting indicates that the system will not copy the Machine Hrs Simulated to Machine Hrs Std during the 'Set Standard from Simulated' cost update program and that the Machine Hrs Std will be maintained manually.

  • Copy from Simulated: This setting indicates that the system will copy the Machine Hrs Simulated to Machine Hrs Standard during the 'Set Standard from Simulated' cost update program. When this value is set, the Machine Hrs, Standard, is disabled and is maintained by the Cost Rollup process.


Machine Hrs, Sim:  The value of Simulated Machine Hrs for the Operation, which is manually maintained by the user. If the 'Machine Std Option' is set to 'Copy from Simulated', then this value is copied to the 'Machine Hrs, Std' during the Cost Rollup process, which is then used in calculating standards. If the Machine Standard Option is set to Manual, then this field is for reference only and is not copied to 'Machine Hrs, Std'. If 'Machine Type' is 'Per Batch' or 'Per Piece', this value must be greater than 0.

EXAMPLE image.png  EXAMPLE  For this Operation, if the machine takes 1 and half hours to process each component ('Machine Type' is 'Per Piece'), set this 'Machine Hrs, Sim' as 1.5.

Machine Hrs Std:  The value of Std Machine Hrs for the Operation, which is copied from the Simulated Machine Hrs during the Cost Rollup process, if the 'Machine Std Option' is set to 'Copy from Simulated'. Otherwise, this field has to be set manually by the user. The value in this field is then used to calculate standards. This value is also the Machine Time used in the Work Order Operation Scheduling. If 'Machine Type' is 'Per Batch' or 'Per Piece', this value must be greater than 0.

EXAMPLE image.png  EXAMPLE 

  • If the 'Machine Std Option' is set as 'Copy from Simulated', considering our example above, the 'Machine Hrs Std' will be set to 1.5 during the cost rollup process.

  • If the 'Machine Std Option' is set as 'Manual Entry', then set this to a desired numerical value.


Subcontract Tab

Fields
 

Subcontract Lead Time:  Applies only if the Operation Type is Subcontract. Subcontract Lead Time is the total # of days from when the assembly leaves your facility until it returns. So, it includes the time that (a) it is shipped or moved from the production facility and arrives at the vendor’s facility plus (b) the time that it is at the vendor’s facility plus (c) the time required to ship it back and, if required, inspected before it goes back to the production floor. This is a manual entry and is not calculated by the system.

EXAMPLE image.png  EXAMPLE  Considering in a Subcontract Operation, it takes five days for a product assembly to go to a Vendor, be processed by the Vendor, and return to us (the production facility), then set this 'Subcontract Lead Time' as 5.


Phase In Tab


Add Revision:  The Item Revision under which this Operation is effective. Even if Revision Control is not active, all new items are given a Revision # of 000000, as the initial revision.

NOTE image.png  NOTE  The 'Revision Status' should not be at 'Implemented'.

Add Date:  The Effective Date (start date) of this Operation will be included on the extracted WO Routing. Any WOs that have an effective date equal to, or greater than, this date will include this Operation (assuming the Add Status below is “Implemented”, and a Delete Effectivity does not exclude it).

Add Status:  The status of the Phase In Engineering Revision:

  • Pending:  User-defined usage.

  • Released:  User-defined usage.

  • Implemented:  Only Operations with a Status of Implemented are included in the Work Order Operations extract.


NOTE image.png  NOTE  If the 'Eng Revision Active' is checked on the Division Master, when adding Routing Operations using a revision other than '000000' (the system created value), the 'Add Date' and 'Add Status' will be initially left blank. When the revision status is updated to 'Implemented', the 'Add Date' and 'Add Status' will be updated to the 'Start Date' and 'Revision Status' of the selected Engineering Item Revision.


Phase Out Tab

Fields
 

Delete Revision:  The Item Revision under which this Operation is phased out. If Revision Control is not active, then the Delete Date and the Delete Status (below) are input by the user.

NOTE image.png  NOTE  The 'Revision Status' should not be at 'Implemented'.

Delete Date:  Beginning with the date entered here, this Operation will not be included in extracted Operations as long as the Delete Status is 'Implemented'. If the Delete Status is not 'Implemented', then this Operation will still be extracted.

Delete Status:  The status of the Phase Out (Delete) Engineering Revision.

  • Pending:  User-defined usage.

  • Released:  User-defined usage.

  • Implemented:  Only Revisions that have a status of implemented will impact the Work Order Operations extract.


Options Tab
 

Allow Accept:  Generally only set on the last Operation of the routing and is automatically set by the system on the last Operation (as Operations are added). If checked, completions directly to inventory (stock) may be performed. This field may be manually set on any Operation where completions to inventory are possible (prior to the last Operation).

Schedule Type:  This field defines the type of Operation regarding scheduling and capacity planning.

  • Labor Only

  • Machine Only

  • Subcontract & Labor
     

Alternate Code:  Assigning an Alternate Code to the Operation identifies this as an Alternate Operation. If an Alternate Operation Code is selected when the Routing is extracted, then all Operations matching the specified Alternate Operation value are extracted, in addition to any Operations with a blank Alternate Code.

Alternate Operations are also affected by two settings from the Division Master. If the 'Alternate Routings Exclude Standard Ops' is True, then only Operations with an alternate code matching the alternate code selected during the extract of Operations will be extracted. If the setting is False, then Operations matching the selected alternate code, plus any Operations with a blank alternate code, will be extracted.

When extracting Operations for either a Rework of Refurb Work Order, only Operations with an alternate code matching the 'Rework-Refurb WO Operation Code' value on the Division Master Shop Floor Control Tab will be extracted, and will not include Operations with a blank alternated code, regardless of the 'Alternate Routings Exclude Standard Ops' setting.

Move/Complete:  Indicates whether Items are moved to the next Operation or not when this Operation is completed. Options are:

  • Complete & Move in 1-step:  Processing completes the specified quantity and moves that quantity to the next Operation, in one step, making them available at that Operation.

  • Complete & Move Separately:  The processing quantity complete and the move processes are done in separate steps.

  • Complete (Concurrent Only):  Used for Concurrent Operations. Completes qty reported at each Concurrent Operation.

  • Neither (Last Operation): Completions are not allowed at the last Operation, but instead are recorded by the Work Order Receipt process.


NOTE image.png  NOTE  This 'Move/Complete' field is not editable and during the creation of a Routing Operation on the new page, it defaults to 'Complete (Concurrent Only)' for Concurrent Operations and 'Complete & Move in 1-step' for non-Concurrent Operations. After saving the record, the system updates this field to the appropriate value as shown in the below table:

S No

Condition

'Move/Complete' value

1

If Concurrent and last Operation (last in the context of a Concurrent Operation means the last Operation between all Concurrent Operations with the same 'Concurrent Seq' value)

Complete & Move Separately

2

If Concurrent and not last Operation

Complete (Concurrent Only)

3

If non-Concurrent, not Labor, and last Operation

Neither (Last Operation)

4

If non-Concurrent, not Labor, and not last Operation

OR
If non-Concurrent and Labor Operation

Complete & Move in 1-step


EXAMPLE image.png  EXAMPLE  Consider the user creates a new Routing Master and clicks Add Standard Operation button to create Operation '10', the 'Move/Complete' in the new Routing Operation page defaults to 'Complete & Move in 1-step'.

  • When the user saves the Operation '10', the 'Move/Complete' will be updated as 'Neither (Last Operation)', because it is the only Operation on the Routing Master.

  • When the user creates another Operation '20', the 'Move/Complete' on the new Operation '20' will be updated as 'Neither (Last Operation)'. And the 'Move/Complete' on the previous Operation '10' will be updated to 'Complete & Move in 1-step'.


Backflush Labor at Qty Complete:  Automatically adds std labor costs to Work Order as quantities are reported complete at this Operation.

Labor Backflush Txn User:  If the Backflush Labor at Qty Complete option is used, this field provides the Mfg User and hourly rate that will be used. If left blank, the transaction will be stamped with the login user and their employee rate.

Require Issue of Components to Complete:  When checked, all components must be issued to the Work Order Operation using this routing in order to book the Qty Move Transaction.


Modifiers Tab
 

Move Hours:  This value represents the amount of time required to move the assembly from this Operation to the next Operation.

NOTE image.png  NOTE  Set to 0 if the 'Operation Type' is 'Concurrent Operation'.

EXAMPLE image.png  EXAMPLE  Considering it takes an hour to move/transfer the product assembly from one Operation to the next Operation, set this 'Move Hours' as 1.

Scrap Factor(decimal):  This will represent the amount of scrap expected during this Operation. This is not yet supported.

Run Hours Divided By:  This is a user-maintained field that provides for high volume Operations. The values entered for Setup Hrs, Run Hrs, and Machine Hrs will be divided by this # for scheduling purposes.

EXAMPLE image.png  EXAMPLE  If 10 pcs are produced each minute at this Operation, the user would enter 600 here (10 pcs per minute times 60 minutes per hour), so the system would calculate the run time entered previously as the run time for 10 pieces, not one.


SEE ALSO
 

Routing Master
Shop Floor Overview
Settings
Routing Operations
Routing-Operations
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