MAPICS ERP for iSeries Enterprise Product Data Management Concepts Guide

Document Number SB35-0450-4

Published by MAPICS, Inc. in Alpharetta, Georgia

Notices
Changes are made periodically to the information herein; any such changes will be reported in subsequent revision. This document contains examples of data and reports used in daily business operations. To illustrate them as completely as possible, the examples contain the names of individuals, companies, brands, and products. All of these names are fictitious, and any similarity to the names and addresses used by an actual business enterprise is entirely coincidental.

Trademarks and service marks

MAPICS ERP is a trademark of MAPICS, Inc. iSeries is a registered trademark of the IBM Corporation in the United States and/or other countries. Microsoft and Windows are trademarks of Microsoft Corporation. AutoCad is a registered trademark of Autodesk, Inc. All other brand and product names may be trademarks of their respective owners.

Fifth Edition (December 2001)

This edition applies to the Enterprise Product Data Management application, program number 5733-M8E, for the MAPICS ERP for iSeries, Version 2, Release 7, and to all subsequent releases and modifications until otherwise indicated in new editions. Make sure you are using the correct edition for the level of the product. Order publications through your MAPICS, Inc. representative. Publications are not stocked at the address given below. A form for your comments appears at the back of this publication. If the form has been removed, address your comments to: MAPICS, Inc. 1000 Windward Concourse Parkway Suite 100 Alpharetta, Georgia 30005 USA Attn: Information Development When you send information to MAPICS, Inc., you grant MAPICS, Inc. a non-exclusive right to use or distribute the information in any way it believes appropriate without incurring any obligation to you. 1997, 2001 MAPICS, Inc. All rights reserved.

To the reader
This book contains the information you need to understand this application. The information in this book applies only to MAPICS ERP. For a complete list of the books in the MAPICS ERP library, see the bibliography included on the MAPICS documentation CD. Chapter 1 "Enterprise Product Data Management" introduces EPDM and explains the migration process. Chapter 2 "Installation Considerations" explains what happens when you migrate your data from PDM. Chapter 3 "Sites and Facilities" introduces the Sites object and explains both production and simulation sites as well as facilities. Chapter 4 "Items, Routings, and Bills of Material" explains how items, routings, and bills make up an item process. Chapter 5 "Engineering Changes" explains how engineering records can be maintained and copied from site to site. Chapter 6 "Costing" explains Costing for EPDM. Chapter 7 "Offline EPDM" describes file maintenance and the CAD interface on the iSeries.

Before you begin

Complete the following training if you do not have equivalent knowledge: iSeries system education for the basic operating concepts of the iSeries system. Education on how to use a Windows application.

What this book contains

This book contains information about the design of Enterprise Product Data Management. If you have any questions or comments about this book, note them on the Evaluation Form in the back of the book and mail the form. If the form has been removed, mail your comments to the address on the back of the title page of this publication.

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Summary of changes
The following changes were made to the EPDM application for release 7: New fields were added to accommodate the integration of MAPICS ERP and the new Cameleon configurator.

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Table of Contents

To the reader ...............................................................................................................ii Summary of changes...................................................................................................iii Table of Contents ...................................................................................................................iv Chapter 1: Enterprise Product Data Management ..............................................................1 Introduction ..................................................................................................................1 EPDM item processes .................................................................................................3 Migration from PDM to EPDM .....................................................................................5 Standard features ........................................................................................................9 EPDM direct interface to other applications ................................................................14 EPDM File Relationships .............................................................................................16 Chapter 2: Installation Considerations ...............................................................................19 Introduction ..................................................................................................................19 Installing and tailoring EPDM.......................................................................................19 Creating the default site...............................................................................................20 Migrating PDM engineering records to EPDM.............................................................20 Activating EPDM..........................................................................................................24 Migrating from multiple PDM environments to EPDM .................................................24 Chapter 3: Sites and Facilities .............................................................................................25 Introduction ..................................................................................................................25 Defining facilities..........................................................................................................26 Defining production sites .............................................................................................26 Copying engineering records between sites................................................................30 Defining a facility..........................................................................................................30 Chapter 4: Items, Routings, and Bills..................................................................................33 Introduction ..................................................................................................................33 Defining items ..............................................................................................................33 Revision identification across MAPICS .......................................................................39 Maintaining items and item revisions...........................................................................39 Defining routings..........................................................................................................40 Maintaining routings.....................................................................................................43 EPDM bills of material .................................................................................................43 Maintaining bills of material .........................................................................................46

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EPDM Item Processes.................................................................................................46 Maintaining item processes .........................................................................................47 Chapter 5: Engineering Changes.........................................................................................49 Introduction ..................................................................................................................49 Copy of engineering records........................................................................................50 Releasing engineering records from EPDM ................................................................51 Chapter 6: Costing ................................................................................................................55 Introduction ..................................................................................................................55 EPDM and costing .......................................................................................................55 Tailoring summary cost fields and headings ...............................................................57 Additional cost fields ....................................................................................................58 Rolling cost from current to standard...........................................................................59 Enhanced cost simulation............................................................................................60 Cost generation ...........................................................................................................60 Euro currency considerations ......................................................................................60 Chapter 7: Offline EPDM .......................................................................................................61 Introduction ..................................................................................................................61 Offline file maintenance ...............................................................................................62 CAD interface ..............................................................................................................63 Appendix A: Offline file load and data entry.......................................................................73 Creating an offline file ..................................................................................................74 Viewing and printing EPDM file record layouts............................................................75 Entering information into the offline files......................................................................76 Loading offline files into EPDM....................................................................................76 Entering changes and deletions ..................................................................................77 Site Master (SITMSTX#) file ........................................................................................77 Item Enterprise (ITMENTX#) file .................................................................................78 Item Revision (ITMREVX#) file ....................................................................................79 Facility Master (FACMSTX#) file .................................................................................82 Product Structure Header (PSTHDRX#) file................................................................83 Product Structure Detail (PSTDTLX#) file ...................................................................84 Routing Header (RTGHDRX#) file...............................................................................85 Routing (RTGOPRX#) file............................................................................................86 Item Process (ITMPRCX#) file.....................................................................................87 Appendix B: Cost Calculations and Feature/Option Definitions ......................................89 Introduction ..................................................................................................................89 Cost formula used for material.....................................................................................90

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Cost formulas used when cost technique code = T.....................................................91 Cost formulas used when cost technique code = R ....................................................91 Labor and Machine Costs............................................................................................93 Manufacturing Overhead .............................................................................................95 Outside operations.......................................................................................................97 Cost roll-up logic ..........................................................................................................98 Feature/options handling (includes discussion of phantoms) .....................................99 Glossary ..................................................................................................................................101 Index ........................................................................................................................................103

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Chapter 1: Enterprise Product Data Management

Introduction ..................................................................................................................1 EPDM item processes .................................................................................................3 Migration from PDM to EPDM .....................................................................................5 Standard features ........................................................................................................9 EPDM direct interface to other applications ................................................................14 EPDM File Relationships .............................................................................................16

Introduction
Welcome to Enterprise Product Data Management (EPDM). MAPICS EPDM is an engineering application for both single site and multi-site organizations. EPDM organizes, maintains, and presents the product engineering data to a manufacturing organization. This data includes information about inventory items, such as raw materials, purchase parts, subassemblies, and assemblies, in structural parent/component relationships. EPDM provides for multiple: Sites Item revisions Routing versions Bills of material Item processes

With EPDM you can define one or more production sites, used for manufacturing, and one or more simulation sites which are used for planning purposes only. For each site, there can be multiple revisions of an item that are based on costing, engineering or other differences. By creating revisions for an item, you can differentiate an item through different phases of design and production. Both inventory items and non-inventory items are referred to as item revisions. There can also be multiple bills of material (BoMs) for each parent item. In a BoM, a parent item is composed of one or more component items and one or more levels of components. Because each item can have different bills of material, you can define bills that reflect the various interests of the engineer using the bill. For example, a design engineer can create a bill of material for an item that reflects the designers point of view, while a manufacturing engineer might restructure the bill to more closely fit the manufacturing facilities and available components that produce the product.

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In addition to a standard sequence of operations, called routings, multiple versions of routings can be defined for each item. A routing version can vary, for example, by facilities used, sequence of operations, and time allotted for each operation. An item process is used to uniquely define an item revision. It can be associated with a BoM and a routing version, within a site. An item must have at least one primary process and can have many alternate processes. EPDM allows you to copy records from an enterprise-wide item master file to multiple sites. An enterprise item helps you define an item across sites consistently. When you create an item for the first time, you add site-item-revision information to the Item Revisions object, and enter the item number in the Enterprise Items object. Whenever you create an item that is already in Enterprise Items, you receive a warning message that the item already exists. This helps to ensure that an item is defined only once within the enterprise of site-item-revision records.

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EPDM Sites

Item
Versions

BoM

Revision
Versions

BoM

+
Revision BoM

+
Routing

Item Process

EPDM item processes

Engineering records that include item revisions, bills of material, and routings can be defined, maintained, and costed for each site. Item processes link a bill of material with a routing for a specific item revision. An item must have at least one primary process and can have many alternate processes. An item process, primary or alternate, is differentiated by an effective date range. Primary process effective dates cannot overlap each other, but alternate process effective dates can. If you have only one primary process, it has no end date. When you create a second primary process, the first ends when the second begins. Only primary item processes are used in product costing, master schedule planning, and material requirements planning. Alternate processes can be used to override a primary process at the time of order entry or during a material requirement planning release of a planned order. You can also use alternate processes to provide different routings through the manufacturing process or to allow for different materials to be used in an alternate bill of material.

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Copying engineering records

EPDM manages and costs engineering records by site in a multi-site organization. You can copy engineering records from site to site and you can use site definitions to create your own costing scenarios. This copy function can save entry time when sites have the same item records. You might create records at a design engineering site, copy them to a manufacturing engineering site, and finally copy them to a production site. EPDM has three powerful utilities you can use to copy engineering records between sites: Item Revision Copy of an item, single-level bill of material, or routing Item Revision Mass Indented Copy of an indented bill with all associated items, routings, and facilities Site Copy of all engineering records in one site to another site

The Item Revision Copy option is usually used to copy an item within a site. The Item Revision Mass copy is often used to copy engineering records from one site to another site.

Comparing engineering records

EPDM uses the MAPICS client server architecture that allows you to take a close look at engineering records. You can compare differences between two enterprise items, item revisions, bills, routings, facilities, or processes by record or by field within a record. You can quickly see and interpret differences in: Cost from one item to another Bills or routings from one item to another Item processes from one item to another

Receiving engineering records

Although you can create engineering records interactively in EPDM, you can also load existing engineering records to the EPDM information base through EPDM Offline functions on the iSeries. EPDM receives engineering records from: PDM during migration CAD or other systems iSeries Offline file maintenance

EPDM receives engineering records in these formats: CAD systems format MAPICS ERP for iSeries Release 7 formats User-defined format

See Chapter 2 Installation Considerations and Chapter 7 Offline EPDM for more information. The MAPICS file record layout is explained in Chapter 7.

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Migration from PDM to EPDM

In EPDM, the process of upgrading from Product Data Management (PDM) to EPDM is called migration. During migration, EPDM receives engineering records from PDM. Starting in release 6, PDM is not a required application for EPDM, However, even if PDM is not installed, some of the MAPICS applications, such as CRP and COM, still use the Item Master file from the PDM database, because they have not been made EPDM-enabled yet. When EPDM is active, every application function that is enabled to use EPDM checks the site field in the warehouse record to determine which engineering record to use. A warehouse must have a site entry if EPDM is active. When EPDM is installed in a system where PDM has previously been installed and active, information in the item, bill of material, routing and production facility files in PDM must be migrated to the EPDM Enterprise Items, Item Revisions, BoMs, Routings, Facilities, and Item Processes objects. PDM data can be migrated multiple times. However, once EPDM is activated, the PDM files can no longer be migrated or maintained. The migrated items in the Item Revisions object are now considered released items. From this point on, whenever these migrated/released items are maintained in EPDM, the updates are also made to the PDM Item Master files. When a user creates a new item revision in EPDM, it must be released in order to be included in the PDM Item Master and therefore available to applications that are not EPDM enabled. The released items will have their records in the Item Master A, B, and C files updated with additions and changes from the item revision A, B, and C files. When PDM data is migrated to EPDM, it is restructured with new key fields. All engineering records are organized by site. In EPDM, the Item Master file is called Item Revision and has three key fields: site, item, and revision. The migration process assigns a blank revision to the PDM records. Bills of materials, routings and facilities are also organized by the site field. EPDM requires that you define a production site that is used for migrating from a PDM information base. The default site that serves as the link between PDM and EPDM must be a production site. This default site is used to bring any existing PDM engineering records into EPDM. From Migration to Item Release 1. 2. 3. Migrate PDM engineering records. Verify that the migration was successful. Activate the EPDM interface. Note: At this point the PDM application can no longer be used. The PDM files remain on the system, but with exception to the Item Master file, are no longer updated. The PDM application is deinstalled. The items that were migrated are now in released status. Also at this point, the PDM records can no longer be migrated again. When migration process is completed and new items are created in EPDM, they have to be manually released so that non EPDM enabled applications can have access to the item revision information via the information stored in the Item Master file.

4.

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Defining sites
When you create an EPDM site, you can choose to define either a production or a simulation site. Once a site is designated as a simulation site or a production site, you cannot change the designation. However you can copy a site to another site and make the second site the other type. The simulation site is used within EPDM; you cannot release orders from a simulation site. Use simulation sites as temporary work areas to analyze planned engineering changes and predict and manage costs. You can copy engineering records from a production site into a simulation site and change cost sensitive information, then roll up costs to see the results. Once the results are complete for a simulation site, you can delete the site or copy it to a production site. You can use site definitions to group engineering records into your own categories, such as a group of engineering records for design engineering and another group for manufacturing engineering. Engineers can use site definitions to create new products or to convert a bill of material used in the design of a product to a bill of material used for manufacturing that product. After the manufacturing bill of material is final, it can be copied back to the production site with a change in the revision level to differentiate it from earlier items and bills. In a multi-site environment, warehouses are linked to a single site. However, multiple sites can use the same items and their revisions, BoMs, routings, operations, and facilities. EPDM also stores costing information in the Sites object that keeps track of when the last cost generations, full or simulated, were performed. EPDM tracks four dates for cost generations: Standard Full Current Full Standard Simulated Current Simulated

Use CAS to set up security for each site. You can give each user the authority to view or maintain information for that site. See the Cross Application Support User Guide for more information on setting up security.

Defining facilities
You define facilities that can in turn be used to identify where operations are performed when you create routings. Each facility belongs to a site and it can be a work center, workstation or a production line. A facility is where an item is produced. See Chapter 3 Sites and Facilities for more information.

Defining items and revisions

An item revision is a unique combination of a site, an item, and a revision. Each revision has an effective date range and can be costed separately. An item revision can have a bill of material, a routing, or both. A revision, in effect, extends the Item Master record to let you define appropriate manufacturing processes and run costs by site, item, and revision. The Item Revisions object manages the references to Item Master for interfacing applications. Item Revisions updates Item Master attributes to use the corresponding Item Revisions attributes. The items in Item Revisions can have different revisions. Each revision has an effective from and effective to date range. Since a revision is part of the site item key, you can develop products

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costs by revision within a site. Master Production Schedule Planning (MPSP) and Material Requirements Planning (MRP) plan orders by revision based on an order's start date, the warehouse that is being planned, and the site the warehouse is assigned to. In a multi-site environment, the Enterprise Items object permits multiple sites to copy item definitions into Item Revision records belonging to a specific site. When you create an item for the first time, you also add the item number to Enterprise Items. The user can copy the item description from Enterprise Items to the item being created at a different site. A user can give the item a unique revision, but it is not required. Items also have an implementation status value that identifies them for: Release to engineering Release to manufacturing Maintain configured bill of material Maintain configured routing Three user defined status codes

Use the Implementation Status object to define statuses for individual item revisions or for a group of items related to a project. After you define the statuses, you can add them to your item definition by using the Item Revisions object. You control the status through the business procedures that you set up within your company. See Chapter 4 Items, Routings, and Bills for more information.

Defining routings and versions

Item 1 can have a unique or a generic routing

Routing 1 Version 1

Item 1

Routing Y

Items can have a unique routing that has the same ID as the item or a generic routing that it shares with other items in the production environment. EPDM lets you define routings for each site that reflect differences in the way an item is manufactured. You can create both unique routings, and generic or shared routings with different versions. Within the same site, version numbers are used to show alternate routings for the same item. Usually one routing version defines the standard way of producing an item while other routing versions define alternate ways. You can use EPDM routing definitions to define: Alternate ways to manufacture an item to avoid a facility bottleneck Temporary or estimated routings before final routings are available Future changes to a process to streamline and speed up operations with new tools

You can also create generic routings when the operation steps are the same for many items and the operation time is identical or the time difference is insignificant. A generic routing defines a set of operations that are common to one or more items. Use generic routings to reap these benefits: You only have to define the routing once for a site. Any changes to the routing can be done once and automatically update for all items that uses the shared routing. Maintenance to a routing is significantly reduced if many items use the same routing.

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You can assign the routing to different item revision records by creating item process records. You can create a generic routing whose ID does not match with any existing Item Revision.

Since you can have many routing versions, each version has a header record that describes the version and also keeps track of cumulative yield information. This information can be used to calculate the adjusted quantity per value for a bill of material paired with the routing version by an item process. The Item Processes object keeps track of the specific item revision-routing bill of material combinations for each site. The Routing Operations object contains records for operations in a routing. Associated with each Routing Operation is the Routing Description, which provides a longer description of the operations. See Chapter 4 Items, Routings, and Bills for more information.

Defining bills of material

When you define a bill of material, you are defining the components of a product. Each component that is part of the bill of material is tied to the item revision for the parent item. An item revision can have many bills of material. Each bill of material, like each routing, has a header record that describes the bill and associates the components of the bill with a standard batch quantity. More than one bill of material for an item is useful in various circumstances. For example, when a bill is used with different routings, it might be necessary to accurately portray the operations where components are used. Your organization might also routinely keep track of different types of bills: as designed, as manufactured, as built. Sometimes at order release you find that a primary component is in short supply, so you want to go to the backup material you usually substitute in this situation. You can release the order with the alternate bill that includes the substitute, and thus avoid having to delete the original component and add the substitute when it comes time to process the order in Inventory Management's Open Material Maintenance function.

Defining item processes

+
Revision BoM

+
Routing

Item Process

Because an item revision can have more than one bill of material and routing, EPDM uses the Item Processes object to store the combinations of bills and routings for a specific item revision record over a period of time. One primary process will always be defined. You can define more primary processes, but they cannot have an overlapping effective date with other primary processes. This primary process serves as the default process that is selected in MPSP, MRP, or IM order entry. These applications select a primary process based on the start date of an order and the item revision in effect on the order's start date. You can also use alternate processes for different purposes. The effective dates for alternate processes can overlap.

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Each item process consists of: Site Item Revision Alternate bill of material ID Routing ID Routing version

You can define an item process with no bill of material or routing. Some purchased items may not have a bill or routing while others may have only a receiving routing. All MAPICS applications that interface with EPDM use the primary process for planning purposes. Alternate processes are used as overrides when necessary during order entry and release. Item processes are used by these applications: EPDM cost generations MPSP and MRP processing and order review Inventory Management manufacturing order entry and release PCC order entry and routing release

Standard features
MAPICS Client Server architecture offers standard functions, including: Maintenance History Reason Tracking Attachments Navigation Bookmarks Workbench API string EZ-Link

For detailed information on MAPICS Client Server standard functions, see the MAPICS Browser Concepts Guide.

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Comparing engineering records

EPDM uses site, enterprise item, item revision, and item process to distinguish engineering records. EPDM gives you a tool for seeing these differences quickly. When you use the Compare function, you can compare only the data entry fields or all fields including systemgenerated and updated fields. Comparing records has two stages. First you can compare two bills and see the differences in components: one has component A, the other doesn't. Then you can compare common components and see differences field by field. Use the EPDM comparison of engineering records to answer questions like these: What is the difference between this bill of material and another? How does this routing version differ from another? What is the difference between these two item processes?

The compare function contrasts data fields within records. For example, one item might cost $100.00 and a very similar item revision, $120.00. You can perform an inquiry that compares the two item revisions and find out what cost elements are different and by how much. Then you can compare the item processes to see if there are differences in the bills or routings.

Controlling how items are processed

EPDM lets you control what can and cannot be done with an item. Use the Implementation Statuses object to define status codes that mark an item as ready or not ready for release to engineering and release to manufacturing. When an item has a status of ready for release to engineering, the item has completed the design phase and can be released to PDM and become an available engineering record for other applications. When an item has a status of ready for release to manufacturing, manufacturing orders can be released to the factory from IM & MRP. Use Implementation Statuses to define a record with a unique Implementation ID and switch settings. This ID can then be inserted in an item revision record to control when the item is released to engineering and manufacturing. You can control how groups of items are processed in a project by giving each item the same implementation ID. You can then change the switch setting in the Implementation record to move all the items through the release to engineering and then manufacturing. Similarly you can control if an item configuration or routing configuration can be maintained.

Costing items
With EPDM you can generate product costs by site. You can do full or selected cost generations. Since you can generate costs by item revision, you can evaluate the cost of producing an item at one site versus another or one item revision versus another. Note that costing cannot be done by item process. PDM and EPDM costing differs in these ways: EPDM costs by item revision, by site, or all item revisions, while PDM costs only by item or all items. EPDM can run product costing for either a production site or a simulation site.

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EPDM automatically calculates yield and adjusted quantity per whenever a change is made through the routing file while you must select a PDM menu option to calculate these two values. EPDM costing reports have new fields: site, revision, and environment.

See Chapter 6 Costing for more information.

Printing reports
EPDM has a Host Printing option available from the File menu and the Where-Used sub menus for some objects. This illustration shows the Item Revisions Report Options with the Operations Cost Sheet selected. The report criteria in the right-hand panel changes with each report you select. To display this dialog select the File menu and the Host Print command.

Select each report by selecting the Print check box.

Include only those records you want and choose how you want the reports to be sorted.

Choose report criteria for each report.

Scroll report list one at a time.

This dialog illustrates selected reports that are submitted in one job to the iSeries when you click Submit. Use the CAS Printer Override Maintenance function to send the report to a selected iSeries printer. The following table lists those EPDM objects whose List or Where-Used windows have a File menu with the Host Print command. Sites and Enterprise Items do not have Host Print commands. EPDM Object Facilities Routings Implementation Statuses Item Revisions Item Processes Bills of Material List Window Yes Yes No Yes Yes Yes Where-Used Window No Yes Yes No No Yes

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Release to engineering
When EPDM is installed and activated, EPDM maintains all changes to the Item Master file. This ensures that there is only one source of maintenance to an engineering record. EPDM uses the Item Release file to track the items that have been released. During PDM migration to EPDM, the Item Release file is created and updated with each PDM item that has been moved to EPDM. After the initial time an item is released, an item can be released interactively, or by using the Mass Item Release option. When EPDM Item Revisions change, EPDM automatically checks Item Release to see whether the item is released. If it has been released, EPDM sends the changes to Item Master through offline maintenance to update the same engineering records there.

Engineering release technique

When a new item revision is created in EPDM with an implementation status of Release, it can be released to Item Master. Release works in these steps: 1. EPDM compares the Item Revision and Item Master records. 2. EPDM creates transactions to make the Item Master record look like the Item Revision record. These include Add and Change transactions for fields that can be keyed but not for system generated fields.

Releasing engineering records to other sites

EPDM allows you to release engineering records in different phases of the design and manufacturing process to other sites by copying them. This release differs from the release to engineering since the Item Release file is not created or updated. Instead EPDM uses the compare function to create difference transactions that are used to update the target site. See Chapter 5 Engineering Changes for more information.

Entering, releasing, and closing manufacturing orders

Manufacturing orders are processed in three stages: Entry Release Close-Out

Inventory Management Order Entry

Inventory Management and Production Control and Costing can extract bills and routings from EPDM. When EPDM is activated, a site is required in a warehouse record. When an item in an EPDM site is selected, you can control the specific revision that is built in Inventory Management by selecting a revision from a list of revisions for an item. IM's order entry will automatically select the primary process from the Item Process file based on the order start date. However, if you want to use an alternate process for an item, you can view a list of item processes and select it.

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During order entry, the interfacing application selects the primary item process based on the order's start date and the item revision in effect on that start date. In case of an overlap of item revision effective dates, Inventory Management uses the most recent revision whose date ranges matches the order date. From this initial selection, you can select from a list of alternate item processes if you need to do so. If no item processes are available, you can enter a bill and routing at this time. Since IM uses the order start date to match to the item process effective date, when there is no start date and the item has a lead time greater than zero, IM calculates a start date using MRP's Quantity Based Lead Time function. When the item's lead time is zero, a start date equal to the system date is assumed. You can also override the start date when necessary.

MRP order review and release

MRP selects a planned order's primary process during the MRP generation and stores it in the planned order record. MRP selects the process by looking at the planned order's start date and determining: The revision from the Item Revision file. When it finds overlapping effective dates, it assigns the one with the latest effective from date. The primary process for the item revision that has the same effective date.

In MRP's order review, you can override the planned orders process with an alternate process. A change to the process automatically firms the order. EPDM's engineering records can be recognized and retrieved by Inventory Management (IM) for manufacturing orders. All items used in that manufacturing order must have been released to engineering so that non EPDM enabled applications can still function. IM's order release cannot take place until all items used in the order have been released to engineering. When an order is released using the EPDM site, IM calculates each component's adjusted quantity per based on the item process used for the order and the yields used in the process. When a component's revision effective dates overlap, IM chooses the component revision with the most recent revision date. Inventory also uses the assigned item process that may or may not be a primary process. As orders are released, IM records a component's revision so that a pick list can be printed with the specific revision. The revision is printed as helpful information; however, MAPICS does not issue or store information by revision. This provides an accurate record of component revisions used in environments where stringent contracts require detailed records. Inventory Management records all information for both EPDM and PDM. Orders are no longer released from PDM once EPDM is activated.

Order close out

Inventory Management carries the released orders that have been added to the Manufacturing Orders Master and Data files over to the order history files. MAPICS archive and restore programs have been enhanced to recognize the new EPDM fields. These new fields are carried in history but are not printed or displayed. When orders are closed out, IM will update average statistics in EPDM's facilities and routing operations file. Facilities are updated during order close out, along with yields and efficiencies.

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EPDM direct interface to other applications

EPDM can communicate directly with these applications: Application PDM Product Data Management Interfacing Application activities Provides engineering records during migration. Receives engineering records through engineering release to the Item Master file. Receives updates from EPDM maintenance. PCC Production Control and Costing MPSP Master Production Schedule Planning MRP Material Requirements Planning IM Inventory Management Receives routings, facilities, and item cost information. EPDM activities Receives engineering records during migration from PDM. Receives engineering records from CAD system and offline maintenance. Maintains all engineering records.

Sends routings, facilities, and associated costs for manufacturing orders.

Receives bills of material, routing, facilities, item processes, and item cost information.

Sends bills of material, routing, facilities, item process and costs to MPSP.

Receives bills of material, item cost information, and item processes for orders.

Sends bills of material, item processes and costs to MRP.

Receives bills, item numbers, and item processes and cost for manufacturing orders. Processes orders: entry, release, and close.

Provides bills of material, item numbers, item process and costs to IM.

EQM Estimating and Quote Management PM Procurement Management PUR Purchasing

Receives engineering records through EPDM's Offline maintenance as needed.

Provides the EQM engineering records to EPDM.

Receives routing and facility information.

Sends routing and facilities for purchase order items.

Receives routing and facility information.

Sends routing and facilities for purchase order items.

EPDM Concepts Guide Chapter 1: Enterprise Product Data Management Page 14

Application COM Customer Order Management PMC Production Monitoring and Control

Interfacing Application activities Receives Product Structure Detail information.

EPDM activities Sends product structure detail for customer order feature/option items.

Receives routings, facilities, and item cost information.

Sends routings, facilities, and associated costs for manufacturing orders.

EPDM Concepts Guide Chapter 1: Enterprise Product Data Management Page 15

EPDM File Relationships

SITMST WHSMST

Site
Groups engineering records within a warehouse. Item revision, facility, BoM, & routing records are all entered by site. A site can be either a production or simulation site.
ITMRVC FACMST ITMRVA ITMRVB

Warehouse
Contains information about the entities where inventory is stored and managed. A site can have more than one warehouse.

Facility
Where an item is made. A group of machines that are used to perform a process, such as a work center, production line, or work station.

Item Revision
Stores the site, item, and revision information that uniquely identifies each item, along with routings, bills of material, and effective date ranges.

ITMREL

Item Release
Tracks items that have been released to engineering.

ITMPRC

ITMENT

ITEMASC

ITEMASB

Item Process
An item revision plus a routing, a bill of material, or both, including effective dates. Item processes can be primary or alternate.

Enterprise Item
List of items used by all sites. Prevents unwanted duplication and provides consistent item definitions across sites.

ITEMASA

Item Master
This file is updated automatically when the item revision file is updated. The Item Master file matches the Item Revision file.

RTGHDR

PSTHDR

Routing
Lists the facilities used and describes the order in which operations are performed to produce an item. Alternate routings within a site use different version numbers.
RTGOPR

Bill of Material
The components of a product. Each component is tied to the item revision for the parent item. An Item Revision can have multiple BoMs.
PSTDTL

ITMPLN

Item Balance
Tracks current quantities for a selected item across all warehouses.

Routing Operation
Contains detailed routing information, such as operation number, operation description, and production facility.

Bill of Material Detail

Contains product structure detail information.

RTGODS

Routing Operation Description

Contains additional routing operation descriptions.

EPDM Concepts Guide Chapter 1: Enterprise Product Data Management Page 16

The diagram above shows the file relationships that support EPDM. The EPDM object that is used to maintain the file is indicated by its application icon that appears in the main MAPICS Browser window. Refer to this diagram for a quick reference to the EPDM files and how they function.

Maintaining user-defined fields

EPDM gives you user-defined fields in all master files that you can use to communicate with your current systems. The fields are easily maintained in EPDM. For example, in the Implementation Status object, you will find three fields you can use with programs you have written to create status codes that can be attached to item records. Records that are brought over from an existing PDM information base do not lose the userdefined fields you have created in the record. These fields are preserved during the migration. Unlike PDM, all EPDM user-defined fields are maintainable. Every master file is also timestamped with a creation date and time and a last updated date and time. The time stamps also record the user ID for the user who created or updated the record.

EPDM Concepts Guide Chapter 1: Enterprise Product Data Management Page 17

EPDM Concepts Guide Chapter 1: Enterprise Product Data Management Page 18

Chapter 2: Installation Considerations

Introduction ..................................................................................................................19 Installing and tailoring EPDM.......................................................................................19 Creating the default site...............................................................................................20 Migrating PDM engineering records to EPDM.............................................................20 Activating EPDM..........................................................................................................24 Migrating from multiple PDM environments to EPDM .................................................24

Introduction
When you install EPDM, you must: Create a default site Identify the default site in the EPDM control file Activate the interface.

To load engineering records from more than one PDM environment, choose one of the PDM environments and follow the steps for one site. Then write a program to unload all records in the remaining PDM environment to an offline file load format. These records can then be loaded to EPDM through the iSeries offline file maintenance. For more information about EPDM Offline Maintenance, see Chapter 7 Offline EPDM.

Installing and tailoring EPDM

EPDM installs seamlessly with all existing MAPICS applications and environments. When EPDM is installed and activated, EPDM drives all file maintenance for items, routings, item processes, and bills of material. All those applications that do not yet communicate directly with EPDM for item information use the Item Master Files that EPDM updates. Refer to the Planning and Installing MAPICS Guide and the Cross Application Support User's Guide for more information about how to install and tailor MAPICS applications. During the tailoring of applications you select option 6 Install/Tailor applications from the CAS main menu. MAPICS is in dedicated mode so that you can select applications and answer questions to tailor your applications and environment.

EPDM Concepts Guide Chapter 2: Installation Considerations Page 19

Creating the default site

After EPDM is installed, use the Create option in the Sites object to define a production site to be used as the default site. Whether you have an existing PDM information base or not, you must create a production site.

Migrating PDM engineering records to EPDM

When you add EPDM to an existing PDM environment, you can transfer the existing PDM information base to EPDM. Follow these steps: 1. At the iSeries MAPICS main menu, select EPDM. 2. Select Migrate PDM's engineering records. 3. Select Migrate engineering records to migrate records from PDM to EPDM but leave the PDM environment active. OR 1. Select Migrate and Activate Interface to migrate records, turn on the interface, and inactivate PDM. You can migrate PDM records but leave PDM active while you become familiar with EPDM. During a training phase, you can introduce EPDM and experiment with using it. When you are ready to go to EPDM for file maintenance, you can repeat the migration but select Migrate and Activate Interface. You can migrate your PDM engineering records more than once until the time that you select migrate and activate.

EPDM Concepts Guide Chapter 2: Installation Considerations Page 20

What happens during migration?

During migration, all the PDM file information is reformatted for the corresponding EPDM file. Migration includes: Item Master Bill of material structure Facility Routing

Item Master
This diagram shows the first of three phases in the Item Master migration.

PDM
B A C A Creates B C

EPDM

Item Master
Item number

Item Revision Master

Site Item number Revision = blank

Creates

Item Process

Site Item number Revision = blank

When migration is started, all of PDM's engineering records are reformatted in EPDM files. This diagram shows how the PDM Item Master file with the key field of Item Number is migrated to a new EPDM Item Revision Master file. The migration results in two new key fields added in EPDM: the site identifier set up in the control file and a blank revision field. The migration also creates an enterprise-wide item master file that includes attributes of the low level code and an item description. In the second phase, each item that is migrated from PDM is checked for a bill of material, an item routing, or both. This diagram shows how the migration processes the PDM engineering record in each of these cases. The key fields are indicated by a bold format.

EPDM Concepts Guide Chapter 2: Installation Considerations Page 21

PDM

EPDM Bill of Material

header
Site Parent Item Number Revision = blank Alternate BoM = blank Description Number of Single Level Components Standard Batch Quantity Cumulative Feature/Option Cost

If the item has a Bill of Material...

Updates

Item Process

Creates

Site Item Number Revision = blank Alternate BoM = blank BoM Site = Site BoM Item = Item Number BoM Rev = blank

If the item has a Routing

Updates

Item Process
Site Item Number Revision = blank Alternate BoM = blank Routing ID = Item ID Version = blank Effectivity Dates

Creates

Routing
header
Site Routing ID = Item ID Version = blank Description Number of Routing Operations Number of Additional Descriptions Standard Cumulative Yield Current Cumulative Yield Average Cumulative Yield

If the item has a Bill of Material and a Routing...

Updates

Item Process

Creates

Routing
header

Creates

Bill of Material
header

Site Item Number Revision = blank Alternate BoM = blank Routing ID = Item ID Version = blank BoM Site = Site BoM Item = Item Number BoM Rev = blank

Site Routing ID = Item ID Version = blank Description Number of Routing Operations Number of Additional Descriptions Standard Cumulative Yield Current Cumulative Yield Average Cumulative Yield

Site Parent Item Number Revision = blank Alternate BoM = blank Description Number of Single Level Components Standard Batch Quantity Cumulative Feature/Option Cost

When an item has a bill of material, the migration updates an Item Process record with fields that EPDM can update and use. A product structure header record is also created with information from the Item Master including the parent item number, standard batch quantity and cumulative feature/option cost factor. When an item also has a routing, the migration updates the Item Process record placing the routing identifier in the record and also creates a Routing Header file with a blank version field and other information from the PDM routing file. When an item has only a routing and no bill of material, the migration updates the Item Process and Routing Header records with the pertinent information

EPDM Concepts Guide Chapter 2: Installation Considerations Page 22

Finally, the migration from PDM creates an Item Release file with the default site identified in the EPDM Control file, an item number, and blank revision.

Bill of material
This diagram shows the bill of material migration that is done at the same time that the bill of material header file is created.

PDM

EPDM

Bill of Material
Parent Item User Sequence 1 Component Item User Sequence 2

Creates

BoM
header
Site Parent Item Number Alternate BoM = blank

Creates

BoM
detail
Site Parent Item Number Alternate BoM = blank User Sequence 1 Component Item Component Revision = blank User Sequence 2

Facility
This diagram shows the Facility migration.

PDM

EPDM

Production Facility
Production Facility ID

Creates

Facility
header
Site Facility ID

All facilities that are migrated from PDM are associated with the default site.

EPDM Concepts Guide Chapter 2: Installation Considerations Page 23

Routing
This diagram shows the Routing migration for the routing and routing descriptions.

PDM

EPDM Routing Operations

detail Site Routing ID for Parent Item Version = blank Operation Sequence

Routing
Parent Operation

Creates

Routing
header Site Routing ID for Parent Item Version = blank

Creates

Routing Descriptions
Parent Operation Sequence Description Sequence

Creates

Routing Descriptions
Site Routing ID for Parent Item Version = blank Operation Sequence Description Sequence

Activating EPDM
If you have chosen Migration instead of Migration and Activation, you can check to be sure the migration is successful before you activate EPDM. After you activate EPDM, PDM is deinstalled, and you cannot migrate files from PDM to EPDM again. The migration of PDM files and activation of EPDM are two separate steps to allow you the flexibility to use EPDM and test the migration before going "live" with EPDM. You can perform the migration many times before activating EPDM, but once it is activated, migration cannot be done again.

Migrating from multiple PDM environments to EPDM

PDM customers with more than one PDM environment must write a program to load all engineering records from the various environments to an offline file format to migrate to EPDM. EPDM can then receive the engineering records combined from many sites into the default site defined in the EPDM Control file. You also create enterprise records, bill of material header, routing header, and item process layouts. See Chapter 7 Offline EPDM for more information about this task.

EPDM Concepts Guide Chapter 2: Installation Considerations Page 24

Chapter 3: Sites and Facilities

Introduction ..................................................................................................................25 Defining facilities..........................................................................................................26 Defining production sites .............................................................................................26 Copying engineering records between sites................................................................30 Defining a facility..........................................................................................................30

Introduction
The site object and the concept of site are part of EPDMs organization of engineering records. In PDM, the site is not defined but understood all engineering records belong to an undefined, single site. EPDM uses the concept of site to open up the one site to one item relationship and give you the power to define sites and use them in new ways. The most obvious advantage of using many sites is to group engineering records for your own purposes to reflect actual physical sites that can now have their own engineering records with access to the enterprise-wide Enterprise Item Master file. You can also define sites to mirror an engineering phase process: design, production, and manufacturing. EPDM has two functionally different sites, production and simulation. A production site is needed to migrate engineering records from an existing PDM environment and to control and manage the sharing of item revisions. A production site can be thought of as the "real" site that stores information about your manufacturing operations. EPDM requires that you define at least one production site. When migrating from PDM to EPDM, the warehouse records in the Warehouse master require a site. Simulation sites are used as a workbench for planning, testing, and costing changes in your real production environment. You can copy all engineering records from a working production site to a simulation site. After you have used the simulation site to learn all that you want about costing options and alternative routings and processes, you can delete the simulation site. To gather a history of the changes you made to the simulation site, print a history of maintenance transactions for the site based on user ID or reason codes over a period of time.

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 25

Defining facilities
Facilities are another name for work centers that identify where a step in the manufacturing process is completed. You define facilities in EPDM and associate them with a site. In a repetitive environment, facilities can be workstations or production lines.

Defining production sites

Production sites can be defined to organize and control your manufacturing process in ways that make the most sense for your business goals and standard operations. Create sites to reflect your business model.

Production sites can have many warehouses and many facilities linked to them. They do not share warehouses or facilities, but are defined as distinct sites with separate warehouses and facilities. Define sites that allow you to model, analyze, and improve your own working environments. EPDM requires that you specify whether a site is a production site in your environment or a simulation site.

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 26

This illustration shows some sample production and simulation sites.

Sites
Peachtree Plant Production Atlanta Plant Production Design Engineering Simulation Manufacturing Engineering Simulation Cost Accounting Simulation

Multiple warehouses and facilities

One warehouse and multiple facilities

Bills of Material

Facilities are unique workcenters with different labor rates. Routings are also added.

Cost is run to establish a baseline. Make changes and run again to see the effect of the change.

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 27

Sites in use: production and simulation

This illustration shows an EPDM database with simulation sites and production sites. It also illustrates the way warehouses can be used.

EPDM

Simulation Site=X1

Simulation Site=X2

Production Site=ATL

Production Site=LA

Intersite Orders

Planning Warehouse ATL

Planning Warehouse LA

Demand Warehouse A

Demand Warehouse B

Demand Warehouse C

Warehouses point to the site that they use. This table shows site item revision records for demand warehouses A and B associated with the ATL production site and demand warehouse C associated with LA production site. Demand warehouse A B C C Item X X X Y Site ATL ATL LA LA Site-Item-Revision ATL-X-1 ATL-X-1 LA-X-1 LA-Y-5

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 28

Sites and warehouses

A warehouse points to a site. More than one warehouse can point to a site but it makes sense to do this only if the costs of materials, labor, and machines are comparable for the warehouse. When warehouses and sites are linked, you can delete a warehouse that points to a site. Many warehouses pointing to one site can indicate a central engineering site. However, when you define facilities you should be sure that the facility IDs are unique when labor rates, for example, for a facility differ from site to site. When defining sites and warehouses consider: Do the warehouses manufacture the same products? When the answer is Yes, go on to compare costs: Are purchase costs for the same item equal? Do facilities have the same labor and machine costs?

A common site for many warehouses may only apply if the warehouses are in the same region and there are centralized administration servers.

Defining simulation sites

A simulation site, like a workbench, does not effect the "real" information base. You can create a simulation site, copy engineering records from production site into the simulation site, and manipulate the item processes and costing to investigate manufacturing options. A simulation cannot release manufacturing orders or interface to other applications. You can copy a production site to a simulation site interactively through the client or through offline maintenance on the iSeries.

Simulation Site from Production Site

Production Site Copy all engineering records Costing Simulation Site

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 29

Costing with simulation sites

Use simulation sites to analyze costs by site and item revision. You can also use them to develop new product costs for an upcoming year or store costs from a previous year along with the database that produced the costs. When you create a simulation and copy into the simulation site the engineering records you want to work with, be sure that you run a baseline costing on the records as they exist. Then when you make the changes and run costing, you can see the results in the new costing information. You cannot feedback costs from a simulation to a production site. Simulation sites that are used for "what if" experiments exist to be used and then deleted. They do not have warehouses associated with them. For more information on costing, see Chapter 6 Costing.

Copying engineering records between sites

EPDM allows you to: Copy a single item and its associated engineering records from one site to another. Copy all items and their associated engineering records from a production site to a simulation site. Mass copy all engineering records from one production site to another, adding to the target site all records from the source site that are not already in the target site.

Defining a facility
When you define a facility, you enter a site ID to identify the facility as belonging to the site. Facilities are the work centers of your manufacturing process. They identify not only actual production stages but also reflect the labor rates paid at these stages. As you define facilities for a site, keep in mind the labor costs at each facility, making sure to assign unique facility IDs to correspond to different labor rates.

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 30

The following graphic shows the relationship between the PDM Work Center master file and the EPDM Facility master file:

PDM

EPDM

Production Facility
Production Facility ID

Creates

Facility

Site Facility ID

This graphic shows only the migration for existing PDM users. New users will enter the facility into EPDM. All facilities that are migrated from PDM to EPDM are associated with the default site.

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 31

EPDM Concepts Guide Chapter 3: Sites and Facilities Page 32

Chapter 4: Items, Routings, and Bills

Introduction ..................................................................................................................33 Defining items ..............................................................................................................33 Revision identification across MAPICS .......................................................................39 Maintaining items and item revisions...........................................................................39 Defining routings..........................................................................................................40 Maintaining routings.....................................................................................................43 EPDM bills of material .................................................................................................43 Maintaining bills of material .........................................................................................46 EPDM Item Processes.................................................................................................46 Maintaining item processes .........................................................................................47

Introduction
These are basic definitions for production data management: An item is any raw material, manufactured or purchased part, subassembly, assembly, or end item. A bill of material is a list of components or raw materials and the quantities needed to make an item. A routing is a sequence of operations required to make a manufactured item.

Items, bills of material, and routings are more complex and more powerful in EPDM than PDM. Items can now have revisions, routings can now have versions, and bills of material can now be primary or alternate. They can be used in many different, independent combinations. Because of the complexity of these shared relationships, EPDM uses a concept called the item process. An item process is made up of an item revision plus a routing and a bill of material. An item process record is automatically created with each item revision record that is created.

Defining items
EPDM uses the Item Revision object for item information. The item revision information is stored in three item revision files A, B, and C. File A stores general item information and data from the item master extension file. File B contains product costing information and File C stores purchasing information.

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 33

Each item is identified to the enabled applications by a combination of three key fields: Site Item Revision

The Item Revision object contains records for all sites. Each site-item-revision can have a different routing and bill of material and can be costed separately. EPDM also stores one reference for each item number from the Item Revision A file in a parallel file called Enterprise Items. Items in this file are identified only by item number. This file is an enterprise-wide file for all sites. This helps to ensure that an item is defined only once within the enterprise.

EPDM Item Revision

Stores the site, item, and revision information that uniquely identifies each item.

Enterprise Item
List of items used by all sites. Prevents unwanted duplication and provides consistent item definitions across sites.

C B A

Purchasing information Product costing information

Item Master

General item information and fields from Item Master Extension

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 34

For example, site ATL has defined item I100 in an Item Revisions file. You start to define the same item, I100, for site DET. Rather than create a duplicate item, you can copy the item description from Enterprise Items.

Site ATL

Site DET

Item Revision
Item I100

Item Revision
Item I100

Enterprise Item
Item I100

A note of caution about simulation sites

When you add an item revision record to a simulation site and then delete the simulation site, the record that was added to Enterprise Items is not deleted. You should periodically maintain the Enterprise Items files and remove all item records that are not used in any of your sites. The Enterprise Item record is not automatically deleted for simulation or a production site. You have to manually remove those records.

EPDM item revision control

How and why do items acquire revisions? To answer this question we can look at three essential properties of an item: Form Fit Function

Form is the configuration of an item such as shape, size, density, weight, or other physical properties that identify the item. Fit is the characteristic that allows an item to connect to or become an integral part of another item. Function is the use or performance of an item.

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 35

Engineering changes drive the creation of revisions for an item. When an engineering change affects the form, fit, or function of an item, there cannot be a revision, but a new item must be created. All other changes can result in a revision usually identified as a letter of the alphabet A through Z. You can use up to six characters to designate a revision. Since all revisions of an item are assumed to be interchangeable (form, fit, function), you cannot track inventory by revision. When you do not know an item revision but need to enter it, EPDM displays a list of all revisions for an item in a site.

Extending the item master record

Revisions, in effect, extend the item master record to let you define various manufacturing processes and run costs by site, item, and revision. Manufacturing orders can also be released to build a revision. Enabled programs "see" revisions and follow these rules when selecting a revision: A blank revision is valid. Selection of a revision is done by effective date.

Overlapping revision effective dates

If overlap occurs in the revision effective dates, MPSP and MRP plan the item revision with the latest overlapping start date. Inventory Management order release does the opposite. If overlap occurs in the revision date, IM uses the revision with the earliest start date for an order release. This insures that your oldest revision inventory is used before the newer revisions.

Item life cycle and status codes

An item goes through many phases in the design, production, manufacturing cycle. EPDM introduces the Item Status Code file to store information on where an item is in this cycle. The information is defined as status codes with additional switch settings in the Item Status Code file. A status code can then be entered in the item record in the Implementation Status code fields so that interfacing applications can determine how a particular item should be handled. EPDM delivers four pre-defined switch settings for status codes: Switch 1 = Items ready for release. Switch 2 = Items ready for manufacturing release. Switch 3 = Maintain configured bill of material Switch 4 = Maintain configured routing

EPDM also provides three switch settings that you can define for your own programs.

Mass update of many items

If you are using EPDM, you can use the implementation status code to indicate when item information needs to be released. Entering an item status code in this field lets you specify when a release to engineering and release of manufacturing orders should occur. The item status code has switch settings you can change. This gives you an efficient way to update the status of many items at once. Use this function when you have a group of new item processes designed for simultaneous release as part of a project.

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 36

When the item revisions are created, you can attach a status code of "DES" (Design) to the item revision record that indicates that the items are in a design phase. The predefined switch settings (Switch 1, Ready for release and Switch 2, Ready for manufacturing release) that control the release to engineering and manufacturing order would be set to NO. As the design project is completed, you can change the Switch 1 (Ready for Release) in the Item Status Code Master to Yes. All the items in the project are automatically updated to reflect the new switch setting for Switch 1 of the status code.

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 37

Project in Design Phase Implementation Status

Status Code DES=Design Switch 1=0 (NO) Switch 2=0 (NO)

Item Revision

Release to Engineering?

Item 1

Item 2

Item 3

Yes 1. Change Implementation Status Switch 1 setting from '0' to '1'

Status Code DES=Design Switch 1=0(NO) Switch 2=0(NO)

Status Code DES=Design Switch 1=0(NO) Switch 2=0(NO)

Status Code DES=Design Switch 1=0(NO) Switch 2=0(NO)

Project Milestone: Release to Engineering

Implementation Status
Status Code DES=Design Switch 1=1 (YES) Switch 2=0 (NO)

Item Revision
2. EPDM automatically updates the Implementation Status switch for all items with status code DES.

Item 1

Item 2

Item 3

Status Code DES=Design Switch 1=1(YES) Switch 2=0(NO)

Status Code DES=Design Switch 1=1(YES) Switch 2=0(NO)

Status Code DES=Design Switch 1=1(YES) Switch 2=0(NO)

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 38

Revision identification across MAPICS

EPDM, MPSP, REP, KBC, CA, OBPM, MM, MRP and IM recognize and use the revision IDs in these files: Item Revision EPDM Bill of Materials Item Release Item Process Inventory Management Order Master Inventory Management Release Order Component Inventory Management Order History Planned Order Master Schedule Item Order Order Review

Maintaining items and item revisions

Use the Maintain menu or Create, Change, Delete and Copy buttons on the EPDM toolbar in Item Revisions to create, change, delete and copy item revision records.

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Use the Maintain menu in Enterprise Items or toolbar to create, change and delete item records in the Enterprise Item Master file.

Defining routings
EPDM routings, like item revisions, are linked to a site. Within a site you can define alternate routings and distinguish each variation as a version number. Routings describe the manufacturing process for an item and therefore reflect the real work centers and work sequences in a site. Versioning lets you reflect any flexibility in your manufacturing process that might result in cost differences and time differences. You can have several test versions for a new routing or create versions to be used at a future date when work centers are retooled.

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 40

Item Process Effective From 10/01-10/03 Item Revision + Routing ID / Version + Bill of Material Routing Header

Site Routing ID Version Description Cumulative Yield

Operations Detail
Site Routing ID Version Operation Sequence Facility

Operations Description
Site Routing ID Version Operation Sequence Description

File structure
The routing record in EPDM consists of three files: Routing Header Operations Detail Operations Description

The routing header contains an identifying description for a routing as well as cumulative yield information. The cumulative yield is updated during routing file maintenance and allows each component's adjusted quantity to be calculated based on the routing used to manufacture the item. The adjusted quantity is calculated as necessary for processes such as manufacturing order release. The routing header has three key fields: site, routing ID, and version number. The routing ID is usually the same as the parent item number except when generic routings are used. The routing operation detail and operation description files are the same as these files in PDM with the addition of the site identifier as a key field. Routings are not differentiated by effective date since each item process that combines an item revision, bill of material, and routing has effective dates. A routing takes on the effective date of the item process it is associated with.

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 41

Generic routings
EPDM lets you use a common routing in a site as a generic routing that can be paired with all items that are manufactured using the same operation steps and with the same or close to the same operation times. Some manufacturing processes might have many products but very few routings. A routing is considered generic if it is shared by more than one item.

Routing relationships
Routing versions are closely related since they describe step by step processes that are very similar and result in identical products. This illustration shows two routing versions; one is an automated process and the second is a manual version that requires different and additional facilities (work centers)
Automated Routing Routing Header
site ATLANTA routing id QUA version 001 description Automated Routing cumulative yield 1.0

Manual Routing Routing Header

site ATLANTA routing id QUA version 002 description Manual Routing cumulative yield 1.0

Operations Detail
site ATLANTA routing id QUA version 001 operation sequence 0010 0020 facility WC01 WC01

Operations Detail
site ATLANTA routing id QUA version 002 operation sequence 0010 0020 0030 facility WC02 WC02 WC03

Operations Description
site ATLANTA routing id QUA version 001 operation sequence 0010 description Use workcenter 24 hours a day

Operations Description
site ATLANTA routing id QUA version 002 operation sequence 0030 description Use fixture ABC

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 42

Maintaining routings
Use the Maintain menu in Routings to create, change, delete and copy routings.

To perform a mass change of routings, use the Mass Change option on the Routing Operations Maintain menu. To navigate to the Routing Operations window, select Routing Operations from the Routings Display menu.

EPDM bills of material

EPDM, like PDM, stores a bill of material to record the relationship between parent items and the components that make up the items. The EPDM files are called Product Structure Header and Product Structure Detail. Like item revisions and routings, bills of materials are associated with a site in the header file. The bill of material header also contains summary information about the bill of material's description, standard batch quantity, and number of single-level components. The description is used to identify the bill of material. In PDM, the standard batch quantity and number of single-level components are stored in the Item Master file. During migration from PDM, these two fields, SBQ and Number of single-level components, are relocated to the Product Structure Header.

EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 43

The bill of material detail file gives specific information about a component: standard quantity-per and operation where used. EPDM adds component revision fields to the detail file to accommodate item revisions.

Alternate bills for one parent item

A parent item can have different routings or different components. In either situation, alternate bills of material might be required. Sometimes a parent item may have more than one bill of material to distinguish more than one routing used to manufacture the item. When this is necessary, the operation where-used detail in the bill of material detail file shows the differences in the routings for the parent item. Alternate bills of material can be created to reflect different components needed when other components are unavailable. When various components are used, the component IDs and revisions in the bill of material detail file are different. EPDM assumes that a bill of material header with a blank alternate bill of material ID is the primary bill of material The EPDM bill of material detail file only stores the standard quantity per for a component. Adjusted Quantity per (current) is calculated as needed such as during manufacturing order release, product costing at current, and MPSP and MRP planning runs. The standard quantity is stored instead of the adjusted quantity because item components in a bill can now be matched to more than one routing through the operation where used field. The calculation of quantity per value can now be based on the actual operation. Adjusted Quantity per (standard) is calculated when performing a cost generation at standard. Adjusted Quantity per (average) can be used during a simulated cost generation.

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Item Process Effective From 5/01-5/03

Item Revision

Routing ID / Version

+ Bill of Material

Bill of Material Header

Site Parent item Parent revision Alternate BoM ID Description Standard Batch Quantity

Bill of Material Detail

Site Parent item Parent revision Alternate BoM ID Component Component revision User sequence Operation where used Standard Quantity Per

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Maintaining bills of material

Use the Maintain menu in the EPDM Bills of Material object to create, change, delete and copy bills.

EPDM Item Processes

A routing is associated with a bill of material to create a new EPDM object: the item process. An item process is an engineering record that defines a site-item-revision bill of material and routing over a specific period of time. Item processes can be primary or alternate. A primary process is the process used to manufacture the item. This process can change over time and is recorded by having primary processes that do NOT overlap in effective dates. Primary processes are used during manufacturing order entry and costing, and can be requested in reports or inquires that use information about bills or routings. Alternate processes also define manufacturing for an item but their effective dates can be overlapping. Alternate processes are like primary processes except that they are not used in a product cost generation. They can be used in reporting, as overrides in releasing manufacturing orders, or in creating planned orders in MRP and MPSP. Purchased items might also have an item process so that receiving routings could be defined for the items.

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Maintaining item processes

Use the Maintain menu in Item Processes to create, change, delete and copy item process records. From this menu you can open List windows to work with Bills of Material, Item Revisions, Routings and Sites. You can also choose to release the item associated with item revisions to engineering.

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EPDM Concepts Guide Chapter 4: Items, Routings, and Bills Page 48

Chapter 5: Engineering Changes

Introduction ..................................................................................................................49 Copy of engineering records........................................................................................50 Releasing engineering records from EPDM ................................................................51

Introduction
EPDM lets you control and track engineering changes. This example of a workflow shows how engineering changes can be tracked with EPDM. 1. Activate maintenance history and reason tracking. 2. Define reason codes to mark maintenance as done for a specific engineering change number. You may even rename the reason code description of the field to read "Engineering change number." 3. When changes are made, EPDM requires a reason code, and changes made to engineering records as part of an engineering change are stored in history. 4. Print a maintenance history by reason code (engineering change). EPDM offers various copy functions to help you move engineering records through a workflow and run costs for items. With EPDM you can copy all engineering records from one site to another. If you copy from a production to a simulation you can then analyze the information and experiment with costing. EPDM also offers a mass copy option that is similar to the add option. EPDM adds records from one site to another, but does not overwrite any existing records in the target site. If you select messaging before you begin the copy you will be alerted to the presence of duplicate records.

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Copy of engineering records

EPDM gives you these mass copy functions: Site Copy: From production site to a new site Item Revision Mass Copy: From a source site to a target site

Site copy
You can copy all engineering records in a production site to a new production or simulation site. A simulation site is usually maintained in the system only temporarily. When all costing analysis and reporting is complete, you can run a site delete that deletes all records in a simulation site.

Item revision mass copy

The mass copy of transactions from a source site to a target site is used to copy a single-level or indented bill of material in one site and add it to another site. The bill of material is exploded and component items and all their associated records are also copied. This copy function allows you to copy from the source site and create in the target site itemrevisions records for items in a bill of material. You can choose to copy routings and their facility records and add them to the target site. Item process records can also be copied and created in the target site. Both production and simulation sites can be sources and targets.

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Copy = cooperation and communication

Through the EPDM client, engineering departments can create, own, and copy records from department to department. For example, design engineering creates items and bills of material, and copies these records to an engineering site where routings and item processes are added. Finally, a copy can be done to a production site. The copy function is really a communication function that allows responsibility centers to cooperate and manage a design and production workflow.

Engineering: Design to Manufacturing to Production

1. Create items, bills of material, routings, and item processes. Design Engineering Site

2. Copy all records from a design site to a manufacturing engineering site.

Manufacturing Engineering Site

Primary Process

Alternate Process

3. Copy all records from a from a manufacturing site to production sites.

Production Site
Primary Process

Production Site
Alternate Process

Releasing engineering records from EPDM

EPDM maintains item information in the Item Revision A, B, and C files and corresponding item information in the Item Master A, B, and C files to provide access to item information for those applications which are not enabled for direct access to the Item Revision files. Updating the Item Master information with new information from the Item Revision files is a process you can control through the Release to Engineering and Mass Release to engineering options in the Item Revisions object. EPDM automatically updates the Item Master A, B, and C files with changes to the Item Revisions A, B, and C files. The item number links the Item Revision information with the corresponding records in the Item Master files. While multiple item revision records can have the same item number, in the Item Master files an item number can only be associated with a single item revision. The information in the Item Master files will reflect only the latest item revision information released from EPDM.

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Using Implementation Status records

The Implementation Status object contains records that you set up to represent different categories of item revisions. For example, you might have an implementation status of REL, which you would associate with item revision records that are ready to be released to engineering. Another implementation status might be MAN, which would indicate item revision records that are ready to be released to manufacturing. The Implementation Status object contains fields that help you manage the release of item revision information. The values that you assign to these fields in each Implementation Status record reflects the readiness for release which is indicated by that Implementation Status. Implementation Status field Release to engineering Release to manufacturing Indicates Item revision has completed the engineering design phase and can be released to engineering. For IM, MRP, and MPSP, whether a manufacturing order containing the item revision can be released to manufacturing. Allows a configured bill of material and item process to be maintained. Allows a configured routing to be maintained Users choice. You can change the label, or name, assigned to these fields to reflect your usage.

Maintain configured bill of material Maintain configured routing User definable 1, 2, and 3

Each of these Implementation Status fields is a Yes/No switch. When you create an Implementation Status record, you set the value, Yes or No, that you want to apply to that particular implementation status. A value of No prevents the release associated with that field. In the Item Revision object, you select the Implementation Status that you want to assign to an individual item revision record. For example, if you have added Item 1 Revision Z for Site A in EPDM, you could assign REL to the Implementation status field in that new item revision record. This implementation status indicates that the new item revision is ready to be released to engineering. You can then subset the list of item revisions, using the Implementation status field value of REL as the subset criteria, to see a list of those item revisions that are ready to release to engineering.

Mass release
In some situations, you might want to release multiple items to PDM. If you have just installed MAPICS, you might want to load your item data into EPDM, then release all of it to PDM at one time. If you are already using EPDM, you might have an engineering change that affects more than one item. In these situations, you want to update PDM with multiple item revisions and the associated item process information at one time, instead of one item at a time. The Mass release option in the Item Revision object gives you a way to update information for multiple items in PDM at one time. This update is important for keeping the item data in EPDM and PDM synchronized. If you want to use an engineering change number to select item revisions for mass release, you need to enter that number in the Implementation Status field or in a user field in each item revision affected by the change. You can then use the Implementation Status field or the user field to subset item revisions by the engineering change number. This subset allows you to

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release only those item revisions that were affected by the engineering change. If you need to ensure that engineering change numbers are valid before processing the release to PDM, use the Implementation Status field.

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EPDM Concepts Guide Chapter 5: Engineering Changes Page 54

Chapter 6: Costing

Introduction ..................................................................................................................55 EPDM and costing .......................................................................................................55 Tailoring summary cost fields and headings ...............................................................57 Additional cost fields ....................................................................................................58 Rolling cost from current to standard...........................................................................59 Enhanced cost simulation............................................................................................60 Cost generation ...........................................................................................................60 Euro currency considerations ......................................................................................60

Introduction
The costing capabilities include: User-tailored headings for summary cost fields Detailed cost fields Roll current costs to standard cost

EPDM supports multiple sites, revisions and routings; EPDM can cost by site and by item revision within a site. You can also use simulation sites in EPDM for extensive cost simulations. Costing is an iSeries batch function for EPDM. Costing is set up through the EPDM control file, and run from the EPDM menus on the iSeries.

EPDM and costing

EPDM offers costing by site or by item revision within a site. EPDM also adds site, revision, and environment to the costing reports and stores costing dates in the site master for both a full and selective costing run.

EPDM automatic calculation

EPDM automatically calculates these values whenever a routing is updated: Cumulative yield through previous operation for each operation Total cumulative yield for parent.

These calculations are automatically done for current, standard, and average costs. EPDM also sets a flag in the routing header to mark the routing change, and resets the recost flag in the item revision B record if the routing is the primary routing for an item. EPDM stores these calculations: Cumulative yield through previous operation is stored in the Routing Operations file

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Operation yield for this operation is stored in the Routing Operations file Cumulative yield for all operations is stored in the Routing header file.

EPDM also automatically calculates the adjusted quantity per (current/standard/average) for each component at the operation where it is first used. EPDM does not store these calculations, but recalculates them and displays them whenever the values must be displayed on a screen or printed in a report. EPDM also stores the standard batch quantity in the bill of material header file and quantity per unit in the bill of material detail file.

EPDM field location

This table summarizes the cost field locations in EPDM. Field Low level code Cumulative yields Number of operations in routing Number of components in bill Standard batch quantity Cumulative Features/Options cost factor Adjusted quantity per (current / standard /average) Calculated as needed EPDM file location Enterprise Item file Routing Header Routing Header Bill of Material Header

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Tailoring summary cost fields and headings

You can now customize the names and lower level detail fields for these summary cost fields: Purchase Purchase Overhead Labor Labor Overhead

Each of these summary cost fields has lower-level detail fields for both current and standard costs. You choose where to allocate these detail cost fields to the four summary fields. Refer to this table for the detail cost fields. Field Setup Labor Run Labor Setup Machine Run Machine Manufacturing Overhead Material Outside Operation Purchase Overhead EPDM file location Labor Setup Run Labor Machine Setup Run Machine Overhead Material Outside Operation Purchase

The Other Cost fields allow you to design your own cost buckets for cost generation. In the EPDM Control File you can allocate these new detail fields to be calculated into the summary field values. The default is no summary field. You can also customize the headings of these summary fields with names up to thirteen characters in length. The EPDM Control file allows you to change the delivered headings and to assign the new detail level cost fields, including the four other cost fields, to a summary cost. You can choose to NOT add the Other Cost field to a summary. This excludes the other cost fields when the cost of an item is calculated.

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Outside operation cost

For routing operations that have a time basis code of C, EPDM tracks the following outside operation costs: Outside operation cost per piece Average outside operation cost per piece

The Machine hours field is accessed if the time basis code is C for calculating overhead over and above the outside cost.

Additional cost fields

EPDM additional cost fields can be tailored and grouped for reports. The fields are summarized in this table. EPDM Standard and Current This level and lower level Other Costs (1-4) Run Labor Setup Labor Setup Machine Run Machine Manufacturing Overhead Material Cost (Purchase - Overhead Operations) Outside Operations # fields

16 8 12

All of these cost fields are added to File B of the Item Revision Master file to allow a more precise definition of cost elements. You can see all of the cost field values on item cost maintenance and item revision information reports and inquiries.

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Rolling cost from current to standard

The EPDM costing function lets you roll costs from current to standard by site at any time. Usually a company performs the cost roll from current to standard at the end of a year. Cost fields in the roll from current to standard are in various files in EPDM. This table summarizes the cost fields that are part of a cost roll from current to standard. The item master for the released item also gets updated. File Item Revision Master Field This level and lower level Costs Labor and Overhead Date of Last Maintenance If current Cost Status Code is to re-cost current, reset the Standard Cost Status Code to re-cost. If the Re-cost flag is set to re-cost current [C], reset the Re-cost flag to both [B]. If the Re-cost Flag is set to recalculate new item current costs [O], reset the flag to both [N]. Site Master Routing Header Routing Operations Type of Cost Generation and Date of Last Cost Generation Moves current cumulative yield to standard Cost Generation Moves current operation yield to standard operation yield. Moves current cumulative yield through previous operation to standard cumulative yield through previous operation. Item Balance Facility Master Sets the Replan Flag if Item/Warehouse exists in the Item Plan File. Moves current dates and codes to standard.

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Enhanced cost simulation

The copy function that allows you to copy all engineering records from site to site, also allows you to create a simulation site for use in costing. All engineering records in a production site can be copied to the cost simulation site, changed, and rolled up without affecting the production site engineering records. When the cost simulation data is complete, you should delete the simulation site with all simulation records. EPDM does not provide for copying field information selectively from a simulation site to update records in another site. If you want to copy an engineering record from a simulation site to a production site, or change costs, you can write a program to move the desired fields or interpret the engineering history file and create offline file maintenance transactions to be applied to the source site file. Be sure that you run a baseline costing when you first copy the records into the site. Then, after changes are made, a costing run provides accurate variances.

Cost generation
EPDM, you can generate costs for a subset of the engineering records in a site or a single item revision at a site. EPDM keeps track of the date of the last cost generation or simulation in each site's master record. The dates of cost generation are displayed on the screen and printed in reports. EPDM item revision files keep track of the dates when an item was last costed for both current and standard costs. These dates are updated for both full cost and selective cost generation.

Euro currency considerations

If your company has converted from a euro-participating local currency to euro currency, the costing amounts in the Item Revision, Routing Operations, and Production Facility objects may be slightly changed. These changes would be due to minor differences in the way euro amounts are rounded versus the way amounts were rounded in the local currency. If your company has converted your local currency to euro, you need to perform a full costing run for either Current or Standard costs or both types of costs. The costing run will rebuild your costs using the detailed cost amounts that were converted to euro.

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Chapter 7: Offline EPDM

Introduction ..................................................................................................................61 Offline file maintenance ...............................................................................................62 CAD interface ..............................................................................................................63

Introduction
You can maintain engineering records interactively on the client, through offline maintenance, or through the Computer Assisted Drawing (CAD) Interface on the server. Select Enterprise Product Data Management from the MAPICS Main Menu. The Enterprise Product Data Management main menu on the iSeries has five options: Costing File Maintenance Migrate PDM engineering records Computer Assisted Drawing (CAD) Interface Activate configurator

Refer to Chapter 6 Costing for more information about option 1 Costing. With option 2 File Maintenance you can add, change, and delete engineering records in these EPDM files: Site Master Item Enterprise Item Revision Item Process Facility Master Product Structure Header Product Structure Detail Routing Header Routing EPDM Control File

This chapter gives more information on file maintenance and record layouts. Refer to Chapter 2 Installation Considerations for more information about option 3 Migrate PDM's engineering records. Option 4 CAD interface has a dual function: you can translate and load bill of material and item revision information in MAPICS formats and AutoCAD* Drawing Extract formats (DXX).

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The CAD Interface Offline load of MAPICS formatted bills and items saves time. It functions much like the mass copy of an indented bill of material on the client side. For example, when you use the CAD interface to load a Bill of Material file, EPDM automatically creates the Bill of Material Header and Item Process records. Doing the same Offline load through Option 2 File Maintenance would require separate steps for each type of record. You can also use the Computer Assisted Drawing (CAD) interface to translate and load bill of material information that has been exported from the AutoCAD program in DXX (Drawing Extract Format). You can define other file formats in the CAD interface import driver. You can write programs to receive incoming files and load them to EPDM. This chapter gives more information about how to use the CAD interface. Press F1 for Help as you work with Offline file maintenance and the CAD interface.

Offline file maintenance

Use EPDM Offline file maintenance to add, change, and delete records in EPDM files in batch mode. This maintenance updates many of the same files that are maintained interactively through the EPDM client. When you want to view the file layout of the EPDM information base, use the CAS (Cross Application Support) Reports function to print the file record layouts. This table lists the physical file names that CAS requires when you are viewing and printing the EPDM offline file maintenance files and the CAD interface import driver file. File Site Master Item Enterprise Item Revision File name SITMSTX# ITMENTX# ITMRVAX# ITMRVBX# ITMRVCX# Facility Master Bill of Material Header Bill of Material Routing Header Routing CAD interface import driver FACMSTX# PSTHDRX# PSTDTLX# RTGHDRX# RTGOPRX# IFADRV

For more information on the offline file maintenance functions available in EPDM, see Appendix A Offline file load and data entry.

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CAD interface
EPDM introduces a way to import information from AutoCAD documents. You can extract the bill of material information from a design engineering library of CAD documents and load it to the EPDM information base. You can make the file load easier by tailoring the CAD information for EPDM --adding site, revision and alternate bill of material information into the CAD document. Or you can work with the files in the CAD interface function before they are loaded to EPDM and add the site, revision and alternate bill of material information. The CAD interface also loads item revision and bill of material information in EPDM format. The CAD interface is an alternate way of loading engineering records from another kind of system to the EPDM information base.

What the EPDM CAD interface expects from the CAD extract file
The AutoCAD drawing files have a three-tiered structure: Drawing, Header Information, and Bill of Material Information. When a CAD drawing is extracted, the output is a drawing extract file with a file extension of DXX. What remains in the extract file is the third tier of information: the Bill of Material.

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This illustration highlights the CAD extract process on the PC.

CAD Drawing File

IT123A.DWG

CAD Drawing

Tier 1

Tier 2 Header Information Engineer: Watkins Drafsman: Kelly Date Approved: 10/26/98 Tier 3 Bill of Material Site= ATL Parent Item= Item 123 Revision=A Alternate BoM ID= 123B

CAD Extract Process

CAD Extract File

EC123A.DXX

Bill of Material Site= ATL Parent Item= Item 123 Revision=A Alternate BoM ID= 123B

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CAD extract attributes read by the CAD interface program

The CAD interface program expects and can read these attributes in the CAD extract file: ALTID CINBR CITRV EDATM EDATO ENGCH ITDSC ITTYP OPWFU PINBR PITRV QTYPR STID UNMSR USRSQ Alternate Bill of Material ID Component Item Number Component Item Revision Effective From Effective To Engineering Change Number Description Item Type Operation Where Used Item Number Item Revision Quantity Per Site Unit of Measure User Sequence.

These identifying attributes can be included in the Bill of Material information in the original AutoCAD drawing file. When they are extracted and the extract file moved to the iSeries MAPCAD library, the CAD interface isolates each attribute and translates it for file maintenance to the EPDM database.

Transfer to the iSeries library

The CAD drawing program operates in the PC world of file extensions. The iSeries doesn't see these extensions, so the EPDM CAD interface relies on a file naming convention that can signal the type of file as well as trigger programs to process. Plan meaningful file names so that the list of file names on the iSeries lets you know what is in the file. MAPICS EPDM delivers six import drivers that "look for" six first characters in the file names to identify the type of information in the incoming file. You can change these naming conventions by editing the import driver and the drill down and translation programs that process the incoming files. You move the output DXF or its summary DXX file to the designated library and it appears on the EPDM CAD interface screen as an incoming file. The CAD Interface processes the incoming files and creates the required transactions for an Offline load to EPDM.

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This diagram illustrates the CAD extract file on the iSeries.

Transfer the extract file to the library on the AS/400

AS/400 MAPCAD Library CAD Interface

The file-naming convention of X* identifies the extract file

XEC123

Bill of Material Site= ATL Parent Item= Item 123 Revision=A Alternate BoM ID= 123B

What the EPDM CAD interface expects from the EPDM-formatted files
The CAD interface has translation programs to load Bill of Material and Item Revision information to the EPDM database. Five of the delivered drivers handle these five types of EPDM records: Item Revision A, B, and C files, and Bill of Material Header and Detail files. The CAD interface driver "sees" these files as complementary and works with them as one package of information. The sixth driver is for the CAD extract file, which was discussed previously. The two most important files are the Item Master A file and the Product Structure of Bill of Material detail file. If you only activate the Bill of Material Detail driver, the EPDM CAD Interface translation program can translate and load all of the other types of records from the Bill of Material Detail file. The other file types, though "invisible" on the iSeries screen, are processed when you activate the Bill of Material Detail driver. The Item Revision A file is required by the CAD Interface program if only item revision information is being loaded. The B and C files are optional. This illustration shows what information is translated in the incoming files and loaded to EPDM. Parent Item
PINBR=200500 CINBR=200501 CINBR=200502 CINBR=200503

EPDM-formatted incoming files

ITMRVAX#

Item Revision A

ITMRVBX#

Item Revision B

ITMRVCX#

Item Revision C

Translate program

PSTDTLX#

Bill of Material Detail

PSTHDRX#

Bill of Material Header

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The CAD interface translation

Once the file is in the interface library, follow these steps to complete the translation.
1 Select option 1 Work with incoming files.
AS/400 Workstation

2 Choose edit or edit and load for an incoming file or files.

3 Translate program edits and translates files.

Incoming file Translate program MAPICS Holding database

4 Select option 2 Work with translated files. 5 Correct errors & send files (status=ready) to offline load.

Translated file

Off-line edit load

Live MAPICS database

Working with the EPDM CAD interface

Choose option 4 CAD interface on the EPDM main menu to display the CAD interface functions. Work with incoming files. Work with translated files. Define Import drivers. Start with option 3 Define the import driver to view the CAD interface programs delivered with EPDM. EPDM delivers six standard drivers. If you have files that do not match one of the standards, you can create your own driver and enter the definition on the import driver screen. These are the programs that translate and load DXX or DXF (AutoCAD extract) and MAPICS formatted Bill of Material and Item Revision records. You also use option 3 to activate or deactivate programs in the CAD interface import driver. You can choose to deactivate a driver and thus exclude files with names that follow the naming convention for that driver from being displayed on the Working with incoming files screen. When you want to customize the CAD interface to process files in other formats, use DFU (Data File Utilities) to edit this import driver (IFADRV). Add additional records for the file types that your new programs translate along with the names of the new programs you created.

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The import driver

The import driver is a record that defines and controls how EPDM processes imported files. Each type of imported file has one record in the import driver. EPDM delivers three import driver processes for the three types of imported files below: CAD extract files EPDM Bill of Material Header and Detail files EPDM Item Revision A, B, and C files.

It is recommended that you process files by engineering change. All records for one engineering change can be placed in files using the driver naming convention specified in the Driver Record Layout table. If your files come from a CAD system and the engineering change number is in the record layout, CAD processing automatically picks up the engineering change number as the reason code. If the engineering change number is not in the DXX or DXF data, the file name is used as the reason code. When reason tracking is turned on, these reason codes must be in EPDM's Reason Master file before the transactions can be successfully processed.

Viewing the import driver

Select Option 3 Define import driver to view the import driver and information about each import file handler.

Short Description of File Type

Library for incoming files

Delivered File Types

Programs used in processing each file type. You can change the display option to INACTIVE.

X, A, B, C, P, and H show the file naming convention for DXF, Item Revision A, B, C, and Bill of Material Detail and Header files.

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File type indicates the file types delivered by MAPICS and the Object shows the file-naming convention that must be maintained for EPDM to recognize the type of file. DXF, DXX PSTDTL PSTHDR ITMRVA ITMRVB ITMRVC CAD Bill of Material Detail Bill of Material Header Item Revision A Item Revision B Item Revision C X* P* H* A* B* C*

Desc is a brief descriptive name for the type of format that is supported by the import file. Objects to include lists the file naming conventions for the objects and the name of the MAPICS library where the objects (files) reside. Library lists the name of the iSeries library where the incoming files are placed. Drill Down Programs run if an import file has a blank file description. This program drills down through the file to find the first engineering change number or parent item number and uses it to identify the engineering record. This description appears in the Text field for incoming programs. Translate Programs translate an import file into an EPDM common file format and define methods for view, delete, and translate. Display incoming file indicates if the driver is active or not. This is the field that you change when you enter 1 for Activate/De-activate in the Opt field.

Work with incoming files

Select Option 1 Work with incoming files to view a list of incoming files and to process information in the files. Files are listed if they meet the criteria set out in the driver, meet naming conventions, and are in the MAPCAD library. Before you select an action to perform on a file, you can enter information that is assigned to all records in the file: Site ID Alternate Bill of Material ID Revision.

This information may already be in the CAD extracted files if it is present in the original CAD drawing file.

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Choose to update these values and enter them before you select files and options.

Option 1 Edit

Action Selects and edits a file for errors against the EPDM files. Translates incoming files to a MAPICS format. Removes the file name from the list.

2 Edit and Load

Selects and edits a file for errors against the EPDM files. Translates the incoming file to a MAPICS format. Removes the file name from the list. If no errors, updates EPDM.

4 Delete 5 View

Deletes the file from the iSeries and the file list. Displays data in the incoming file.

For DXX or DXF files, select and process each file. For offline load files, select a file and the program picks up all files associated by the naming convention.

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Work with translated files

Select Option 2 Work with translated files to view and work with translated files. You can see a status for each file that indicates the outcome of the edit or edit and load processes. The status can be: Ready Errors Loaded Update Change Error free and can be processed by the Edit and Load option. Errors present that must be corrected before loading to EPDM. Updated to EPDM. In process of being updated to EPDM. Variables have been changed in the file.

Status of translated file after edit or edit and load program is run against the incoming file.

Option 1 Edit

Action Selects and edits a file for errors against the EPDM files. Translates file to a MAPICS format. Removes file name from the list. Selects and edits a file for errors against the EPDM files. Translates file to a MAPICS format. Removes file name from the list. If no errors, updates EPDM. Deletes the file from the iSeries and the file list. Displays the file and allows you to correct the errors and update values.

2 Edit and Load

4 Delete 5 View and set variables

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EPDM Concepts Guide Chapter 7: Offline EPDM Page 72

Appendix A: Offline file load and data entry

Creating an offline file ..................................................................................................74 Viewing and printing EPDM file record layouts............................................................75 Entering information into the offline files......................................................................76 Loading offline files into EPDM....................................................................................76 Entering changes and deletions ..................................................................................77 Site Master (SITMSTX#) file ........................................................................................77 Item Enterprise (ITMENTX#) file .................................................................................78 Item Revision (ITMREVX#) file ....................................................................................79 Facility Master (FACMSTX#) file .................................................................................82 Product Structure Header (PSTHDRX#) file................................................................83 Product Structure Detail (PSTDTLX#) file ...................................................................84 Routing Header (RTGHDRX#) file...............................................................................85 Routing (RTGOPRX#) file............................................................................................86 Item Process (ITMPRCX#) file.....................................................................................87 As an alternative to entering master file or transaction data interactively using MAPICS, you can prepare the information offline in files on a separate system. The files that you create or update offline can then be loaded into the MAPICS system and processed by MAPICS. Offline files can be created on a diskette or written to a disk file. For disk offline file load, the disk file resides on the iSeries system, but outside of MAPICS. For diskette offline file load, you enter records into a file created on a floppy, or flexible, disk. The same format requirements apply to both. To use data from offline files in MAPICS, you must: Gather the information to be entered, then create a file with the information on diskette or disk. The file must follow the corresponding file layout. See Viewing and printing EPDM file record layouts for instructions for obtaining the file layout. Load the offline files by selecting a MAPICS menu option.

This appendix describes these activities and files.

EPDM Concepts Guide Appendix A Page 73

Creating an offline file

You can create offline files on diskette or disk. You can create the files in several ways. For example: You can create the records with a user-written program on an offline data entry device, and write them to a disk or diskette file. You can have another system create the records on tape using the required file layout. You copy the tape to disk or diskette. You can have a remote location send the records via telecommunications. You can write them to a disk or diskette file.

It does not matter how or where the records originate. As long as they reside in a disk or diskette file that has the defined file layout, MAPICS can process them.

File format
You can print a copy of the file record layout. The layout gives you the following information for each maintainable field: A brief description of the field Whether the field is alphabetic or numeric (signed or packed) (A/S/P) The starting position of the field in the record (Start) The length of the field For numeric fields, the number of decimal positions in the field (Dec) The short field name (6 characters)

EPDM Concepts Guide Appendix A Page 74

File name
Assign a special name to each file, or use the default name listed here. You must enter the name when you load the file. Master file to be loaded or updated Site Master file Item Enterprise file Item Revision fileA record Item Revision fileB record Item Revision fileC record Facility Master file Product Structure Header file Product Structure Detail file Routing Header file Routing file Item Process file Offline file name (default) SITMSTX# ITMENTX# ITMRVAX# ITMRVBX# ITMRVCX# FACMSTX# PSTHDRX# PSTDTLX# RTGHDRX# RTGOPRX# ITMPRCX#

If you want to translate and load bill of material and item revision information in MAPICS formats and AutoCAD* Drawing Extract format (DXX), use the following offline file name. File to be loaded or updated CAD interface import driver file Offline file name (default) IFADRV

Viewing and printing EPDM file record layouts

Use Cross Application Support to obtain a printed version of the file record layout for the file you will be working with. See the CAS Users Guide for more detailed information. 5. At the CAS main menu, select option 2 Reports. 6. At the Reports menu, select option 5 File Record Layout. 7. To print all EPDM file record layouts, enter 1 in the option field next to Enterprise Product Data Management and press Enter. 8. To print only specific files, enter 1 to select EPDM and press F22 (SHIFT and F10). 9. To print more detailed information, select Print Characteristics. 10. Tab to the entry fields and type the file names of the files you want to see and print. You must use one of the file name shown in the tables above \* MERGEFORMAT . 11. Press Enter.

EPDM Concepts Guide Appendix A Page 75

Entering information into the offline files

Regardless of what offline method you use for entering information, the information in the files must be organized in the layout shown in the file record layout. The file layout shows the fields contained in each file record in the correct sequence for offline entry. The alphabetic/numeric column (A/N) in the layout tables contains important information for setting up the offline files. The letter A indicates alphabetic fields. Numeric fields are indicated by the letters N, S, and P. The letter N indicates a regular numeric field; the letter S represents a signed numeric field. The letter P indicates a numeric field in packed format. All numeric fields must contain zeros or numeric data in each position. Otherwise, data decimal errors will occur and the entry will fail.

Loading offline files into EPDM

When you have finished creating the offline files, you are ready to load the information onto the system. For instructions on how to load master files from offline files, see the CAS Users Guide.

EPDM Concepts Guide Appendix A Page 76

Entering changes and deletions

When you use offline maintenance to change or delete records, follow these guidelines: For required fields and fields you want to change, enter valid data. See the tables later in this appendix for the required fields in each file. For optional fields you do NOT want to change, you must enter all blanks with special characters: To enter all blanks for an alphabetic field, type all asterisks (*). To enter all blanks for a numeric field, type all nines followed by a negative sign (999999999).

To delete a record, enter valid data for required fields only.

Site Master (SITMSTX#) file

The SITMSTX# file is a physical file containing site information. As a convenience, the offline load physical file SITMSTX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the SITMSTX# file in your own user library, using the following command: CRTDUPOBJ OBJ(SITMSTX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/SITMSTX#) MBR(SITMSTX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Site Master Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required to process a site record. Required field Transaction ID Field name TRID39 Value required D0AB0100 D0AB0200 D0AB0300 Reason Code Site identifier Site description Simulation site Data security group code RSCD39 STID39 STDS39 SIMS39 AA0B39 Delete Add Change If reason tracking is on All records D0AB0200 only All records D0AB0200 only Required for All records

Reason for the maintenance Valid site ID Description of the site '0' or '1' Valid security group code

EPDM Concepts Guide Appendix A Page 77

Item Enterprise (ITMENTX#) file

The ITMENTX# file is a physical file containing enterprise item information. As a convenience, the offline load physical file ITMENTX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the ITMENTX# file in your own user library, using the following command: CRTDUPOBJ OBJ(ITMENTX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/ITMENTX#) MBR(ITMENTX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Item Enterprise Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required to process an item enterprise record. Required field Transaction ID Field name TRID41 Value required D0C00100 D0C00200 D0C00300 Reason Code Item number Item description RSCD41 ITNO41 ITDS41 Delete Add Change If reason tracking is on All records D0C00200 only Required for All records

Reason for the maintenance Valid item number Description of the item

EPDM Concepts Guide Appendix A Page 78

Item Revision (ITMREVX#) file

The ITMREVX# file is a logical file across multiple physical files (ITMRVAX#, ITMRVBX#, and ITMRVCX#). The A record is always required. If you do not specify a B record, it is created automatically. For item type 3 and 4, the C record is created automatically unless it is entered during initial offline file load. As a convenience, the three offline load physical files, ITMRVAX#, ITMRVBX#, and ITMRVCX#, and one logical file, ITMREVX#, are provided in a Save File called SFITMREVX# in the AMXLIBX library. If you plan to use these files to load your offline data, you can follow these steps: 1. Restore ITMRVAX#, ITMRVBX#, ITMRVCX#, and ITMREVX# to your user library, using the following command: RSTOBJ OBJ(ITMREVX# ITMRVAX# ITMRVBX# ITMRVCX#) SAVLIB(ITMREVX#) DEV(*SAVF) SAVF(AMXLIBx/SF ITMREVX#) RSTLIB(your library) where x is the first character of the MAPICS environment you are using. 2. If you are entering the data on the iSeries, use Data File Utility (DFU) to establish a data entry session for each of the Item Revision formats (A, B, C). Enter all data for each format (A, B, C). If you are entering data from some other source, make sure that each position of the record has valid data according to the offline file layouts (for example, numeric fields have numeric data). If you have transferred the data to the iSeries by way of a record length (flat) file, you can use the copy file function (CPYF) to copy the data from the record-length file to the appropriate physical file (ITMRVAX#, ITMRVBX#, ITMRVCX#). Specify the no check option for the Record Format Field Mapping option (FMTOPT=*NOCHK). 3. After you have put the data into the offline physical files (ITMRVAX#, ITMRVBX#, ITMRVCX#), select Item Revision offline file maintenance and select the default file (ITMREVX#) in your user library as the file to load. The offline load process copies the data from the offline physical files and properly sequences the records by transaction ID and item number. The following table shows an overview of the Item Revision records and the sequence in which they should be entered. Sequence 1 2 3 Record A B C Description General item information Costing information Purchasing information

EPDM Concepts Guide Appendix A Page 79

Record type A: Item information (ITMRVAX#)

The following fields are required to process an item revision A-record. Required field Transaction ID Field name TRID30 Value required D001AD01 D002AD01 D003AD01 Reason Code Site identifier Item number Item revision Item description RSCD30 STID30 ITNO30 ITRV30 ITDS30 Delete Add Change If reason tracking is on All records All records All records D002AD01 only Required for All records

Reason for the maintenance Valid site ID Valid item number Valid item revision number Description of the item

Record type B: Item information (ITMRVBX#)

The following fields are required for costing information. The site item number and item revision number must match the number you enter for the A record. Required field Transaction ID Field name TRID31 Value required D001AL00 D002AL00 D003AL00 Reason Code Site identifier Item number Item revision RSCD31 STID31 ITNO31 ITRV31 Delete Add Change If reason tracking is on All records All records All records Required for All records

Reason for the maintenance Valid site ID Valid item number Valid item revision number

EPDM Concepts Guide Appendix A Page 80

Record type C: Item information (ITMRVCX#)

The following fields are required for purchasing information. The site item number and item revision number must match the number you enter for the A record. Required field Transaction ID Field name TRID32 Value required D001AW00 D002AW00 D003AW00 Reason Code Site identifier Item number Item revision RSCD32 STID32 ITNO32 ITRV32 Delete Add Change If reason tracking is on All records All records All records Required for All records

Reason for the maintenance Valid site ID Valid item number Valid item revision number

EPDM Concepts Guide Appendix A Page 81

Facility Master (FACMSTX#) file

The FACMSTX# file is a physical file containing facility information. As a convenience, the offline load physical file FACMSTX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the FACMSTX# file in your own user library, using the following command: CRTDUPOBJ OBJ(FACMSTX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/FACMSTX#) MBR(FACMSTX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Facility Master Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required to process a facility record. Required field Transaction ID Field name TRID16 Value required D0FM0100 D0FM0200 D0FM0300 Reason Code Site identifier Production facility ID Production facility description RSCD16 STID16 PFID16 PFDS16 Delete Add Change If reason tracking is on All records All records D0FM0200 only Required for All records

Reason for the maintenance Valid site ID Valid production facility ID Description of the production facility

EPDM Concepts Guide Appendix A Page 82

Product Structure Header (PSTHDRX#) file

The PSTHDRX# file is a physical file containing product structure header information. As a convenience, the offline load physical file PSTHDRX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the PSTHDRX# file in your own user library, using the following command: CRTDUPOBJ OBJ(PSTHDRX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/PSTHDRX#) MBR(PSTHDRX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Product Structure Header Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required to process the header record for a product structure. Required field Transaction ID Field name TRID37 Value required D0CS0100 D0CS0200 D0CS0300 Reason Code Site identifier Product structure description Parent item number Parent item revision number Product structure description RSCD37 STID37 PSHD33 PITM37 PITR37 PSHD37 Delete Add Change If reason tracking is on All records DOCS0200 only All records All records D0CS0200 only Required for All records

Reason for the maintenance Valid site ID Description of the product structure Valid item number Valid item revision number Description of the product structure

EPDM Concepts Guide Appendix A Page 83

Product Structure Detail (PSTDTLX#) file

The PSTDTLX# file is a physical file containing product structure detail information. As a convenience, the offline load physical file PSTDTLX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the PSTDTLX# file in your own user library, using the following command: CRTDUPOBJ OBJ(PSTDTLX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/PSTDTLX#) MBR(PSTDTLX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Product Structure Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required to process the detail record for a product structure. Required field Transaction ID Field name TRID33 Value required D0CU0400 D0CU0500 D0CU0600 D0CU0700 Reason Code Site identifier Parent item number Parent item revision number Component item revision number Component item number RSCD33 STID33 PITM33 PITR33 CITR33 CITM33 Product structure delete Product structure detail record delete Detail record add Detail record change If reason tracking is on All records All records All records All records All records Required for All records

Reason for the maintenance Valid site ID Valid item number Valid item revision number Valid item revision number Valid item number

EPDM Concepts Guide Appendix A Page 84

Routing Header (RTGHDRX#) file

The RTGHDRX# file is a physical file containing routing header information. As a convenience, the offline load physical file RTGHDRX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the RTGHDRX# file in your own user library, using the following command: CRTDUPOBJ OBJ(RTGHDRX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/RTGHDRX#) MBR(RTGHDRX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Routing Header Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required to process the header record for a routing. Required field Transaction ID Field name TRID38 Value required D0C30100 D0C30200 D0C30300 Reason Code Site identifier Routing identifier Routing header description RSCD38 STID38 RTID38 RTHD38 Routing header record delete Routing header record add Routing header record change If reason tracking is on All records All records D0C30200 only Required for All records

Reason for the maintenance Valid site ID Valid routing ID Description of the routing

EPDM Concepts Guide Appendix A Page 85

Routing (RTGOPRX#) file

The RTGOPRX# file is a physical file containing detailed routing information. As a convenience, the offline load physical file RTGOPRX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the RTGOPRX# file in your own user library, using the following command: CRTDUPOBJ OBJ(RTGOPRX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/RTGOPRX#) MBR(RTGOPRX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Routing Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required to process the detail record for a routing. Required field Transaction ID Field name TRID34 Value required D0C4050 0 D0C4080 0 D0C4090 0 D0C4100 0 D0C4110 0 D0C4180 0 D0C4190 0 D0C4200 0 D0C4210 0 D0C4310 0 Reason Code RSCD34 Milestone group remove Routing delete Operation record delete Operation record add Operation record change Routing additional descriptions delete Operation additional description record delete Operation additional description record add Operation additional description record change Milestone group define If reason tracking is on All records All records Required for All records

Reason for the maintenance

Site identifier Routing identifier

STID34 RTID34

Valid site ID Valid routing ID

EPDM Concepts Guide Appendix A Page 86

Production Facility identifier Operation description Operation Sequence

PFID34 OPDS34 OPSQ34

Valid facility ID Description of the operation Sequence # for operation

All records D0C41000o nly All records

Item Process (ITMPRCX#) file

The ITMPRCX# file is a physical file containing item process information. As a convenience, the offline load physical file ITMPRCX# is provided in the AMXLIBx library (where x is the first letter of the environment you are using). If you plan to use this file to load your offline data, it is suggested that you follow these steps: 1. Make a copy of the ITMPRCX# file in your own user library, using the following command: CRTDUPOBJ OBJ(ITMPRCX#) FROMLIB(AMXLIBx) OBJTYPE(*FILE) TOLIB(your library) ADDPFM FILE(your library/ITMPRCX#) MBR(ITMPRCX#) 2. Using Data File Utility (DFU), establish a data entry session for the offline file and enter all of the offline transactions for the file. 3. When you have completed the DFU session, select Product Structure Header Offline Maintenance and specify the offline file in your user library as the file to load. The following fields are required for an item process record. The only offline file load transaction supported for this file is the creation or addition of a new record. You cannot use the offline file load function to change or delete an item process record. Required field Transaction ID Reason Code Site identifier Item number Item revision Description Item revision primary alternate flag Effective from date Field name TRID40 RSCD40 STID40 ITNO40 ITRV40 IPDS40 IPPA40 Value required D0C1020 0 Record add Required for All records If reason tracking is on All records All records All records All records All records

Reason for the addition Valid site ID Valid item number Valid revision number Description of the item process 1 = primary 0 = alternate

EDAM40

Valid calendar date

Primary only

EPDM Concepts Guide Appendix A Page 87

EPDM Concepts Guide Appendix A Page 88

Appendix B: Cost Calculations and Feature/Option Definitions

Introduction ..................................................................................................................89 Cost formula used for material.....................................................................................90 Cost formulas used when cost technique code = T.....................................................91 Cost formulas used when cost technique code = R ....................................................91 Labor and Machine Costs............................................................................................93 Manufacturing Overhead .............................................................................................95 Outside operations.......................................................................................................97 Cost roll-up logic ..........................................................................................................98 Feature/options handling (includes discussion of phantoms) .....................................99

Introduction
Current and standard costs (this level) for an item are calculated using identical formulas, based on Item Revision and Facility fields. The only difference is that current fields are used to develop current costs, and standard fields are used to develop standard costs. An items material, labor, machine, and manufacturing overhead content this level and setup cost per lot are calculated based on the Item type code (ITTYP) and the Cost technique code (CTECH) for the item. If you selected to use facility standard efficiency during application tailoring, the standard efficiency factor for each facility is used to factor the machine and labor hours which are used to calculate the various cost elements for operations occurring in that facility. Item type code = 9: Material this level remains the value contained in the Item Revision record. Labor, machine, and overhead content this level are calculated the same way as for a

Purchased item: Material this level remains the value contained in the Item Revision record. Labor, machine, and overhead content this level are normally zero. Setup cost per lot remains the value in the Item Revision record.

Manufactured item: Material this level is calculated during cost roll-up. Labor, machine, and manufacturing content this level and setup cost per lot are calculated based on the cost technique code (CTECH):

EPDM Concepts Guide Appendix B Page 89

blank T

Uses value entered during Item Revision maintenance Labor hours x labor rate, using the L/O costing table. (The labor hours and the labor rate table code are in the Item Revision B file.) Calculated, based on each active routing operation (see formulas later in this section).

Costs are affected by the following: Item Revision file cost fields or standard lot size. Quantity per in the bill of material (product structure file). Labor hours, labor or overhead code in the Item Revision file, if CTECH=T. L/O costing table rates, if CTECH=T. Rates/percentages or efficiencies (if you chose during tailoring) in the Production Facility file, if CTECH=R. Hours, amounts, yields, or setup crew size in the Routing file, if CTECH=R EPDM Control file (defines which elements are used to compute an items unit cost).

An items recost flag is reset if the Item Revision, Product Structure, or Routing files are changed in the associated fields. You can determine when an items unit cost is recalculated, by running selective or full, current, standard, or both costing.

Cost formula used for material

All costs described below are "this level" costs:

Material Cost:

(A + B) x (C/D)

where: A = component material B = component purchase overhead C = adjusted quantity per D = standard batch quantity (of the parent)

Source of data used in Material cost calculations

Product Structure files: Standard batch quantity (parent) Adjusted quantity per (calculated)

Item Revision B file: Material (components) Purchase overhead (components)

EPDM Concepts Guide Appendix B Page 90

You define a quantity per when you create a bill of material (during product structure file maintenance). Adjusted quantity per is calculated as needed and is not stored in any file. The yield through all previous operations is divided by the yield for all operations and that number is multiplied by the quantity per to arrive at the adjusted quantity per. Only product structure records with a current effective date are used in the calculations.

Cost formulas used when cost technique code = T

All costs described below are "this level" costs: Setup labor: zero Run labor: Labor hours (Item Revision B file) x Labor rate (L/O table) Setup machine: zero Run machine: zero Manufacturing overhead: one of the following: 1. Labor hours (Item Revision B file) x Overhead rate (L/O table), or 2. Run labor (as calculated above) x Overhead percent (L/O table) Note: A negative value in the Labor/Overhead table indicates that the value is a percentage. A positive value indicates that the value is a rate.

Cost formulas used when cost technique code = R

All costs described below are "this level" costs: Time Basis Code: The formulas below should be adjusted by the Time Basis Code for each operation, as follows: TBC 1 2 3 4 5 M P H C Description Hours per unit Hours per 10 units Hours per 100 units Hours per 1,000 units Hours per 10,000 units Minutes per piece Pieces per hour Hours per lot Cost per piece TBC factor 1.0 0.1 0.01 0.001 0.0001 1 divided by 60 1 divided by run labor hours 1 divided by standard lot size 0.016666667 Reciprocal Yield is not used Outside operation Comments

For a time basis code of P, the factor used to compute the run labor amount is "1 divided by run labor hours" and the factor used to compute the run machine amount is "1 divided by machine labor hours". For formulas used when the TBC=C, see Outside operations.

EPDM Concepts Guide Appendix B Page 91

Setup Cost per Lot: The routing operation setup cost per lot is:

(A x B) + {(A x C) / D}

where: A = setup labor hours B = setup labor rate C = machine rate D = setup crew size

All active routing operations are used to compute an items total setup cost per lot.

Source of data used in cost technique code calculations

Routing Operation file: Setup labor hours Setup crew size

Production Facility file: Setup rate Machine rate

EPDM Concepts Guide Appendix B Page 92

Labor and Machine Costs

Setup Labor Cost: The labor and machine setup cost is:

{(A x B) / C} / D

where: A = Setup labor hours (adjusted by TBC factor, if TBC=M) B = Setup labor rate C = Standard lot size D = Standard efficiency, (if tailored to use) Run Labor Cost: The run labor cost is:

{(A x B) x C} / D

where: A = Run labor hours (adjusted by TBC factor) B = Run labor rate C = Yield adjustment (yield through previous operations/yield all operations) D = Standard efficiency, (if tailored to use)

Setup Machine Cost: The setup machine cost is:

{(A x B) / (C x D)} / E

where: A = Setup machine hours (adjusted by TBC factor, if TBC=M) B = Machine rate C = Standard lot size D = Setup crew size E = Standard efficiency, (if tailored to use)

Run Machine Cost: The run machine cost is:

{(A x B) x C} / D

EPDM Concepts Guide Appendix B Page 93

where: A = Run machine hours (adjusted by TBC factor) B = Run machine rate C = Yield adjustment (yield through previous operations/yield all operations) D = Standard efficiency, (if tailored to use)

Source of data used in Labor and Machine cost calculations

Item Revision A file: Standard lot size

Routing files: Setup labor hours Run labor hours (operation) (operation)

Setup machine hours (operation) Run machine hours Setup crew size (operation) (operation)

Yield through previous operations (operation) Yield all operations (header)

Production Facility file: Labor rate Setup rate Machine rate Overhead code Overhead rate/percent Standard efficiency

Note: Yield is not used if TBC=H.

EPDM Concepts Guide Appendix B Page 94

Manufacturing Overhead
Manufacturing overhead calculations use the following elements, which were described previously: 1. Setup labor cost 2. Run labor cost 3. Setup machine cost 4. Run labor cost Since calculations for those elements use yield and efficiency (if tailored), overhead is also affected by yield and efficiency. The following formulas apply when the TBC is not C (outside operation). For TBC=C there is no manufacturing overhead calculated. When the TBC=C, see Outside operations for information on calculating outside operation overhead.

Overhead code = A (Based on machine cost):

(A + B) x C

where: A = Setup machine cost B = Run machine cost C = Overhead percent for code A

Overhead code = B (Based on labor cost):

(A + B) x C

where: A = Setup labor cost B = Run labor cost C = Overhead percent for code B

Overhead code = C (Based on machine hours per unit):

{(A/( B x C) + (D x E)} x F

where: A = Setup machine hours

EPDM Concepts Guide Appendix B Page 95

B = Setup crew size C = Standard lot size D = Run machine hours, adjusted by TBC factor E = Yield adjustment (yield through previous operations/yield all operations) F = Overhead rate for code C

Overhead code = D (Based on machine content + (labor hours/units * labor overhead rates)

{(A/B) + C x D)} x E

where: A = Setup labor hours B = Standard lot size C = Run labor hours, adjusted by TBC D = Yield adjustment (yield through previous operations/yield all operations) E = Overhead rate for code D

Source of data used in Manufacturing Overhead calculations

Production Facility file: Overhead rate/percent

Routing files: Setup labor hours Run labor hours (operation) (operation)

Setup machine hours (operation) Run machine hours Setup crew size (operation (operation)

Yield through previous operations (operation) Yield all operations (header)

Item Revision B file: - Standard lot size

Note: Yield is not used if TBC=H.

EPDM Concepts Guide Appendix B Page 96

Outside operations
If the Time Basis Code (TBC) = C for an active routing operation, outside operation cost is calculated. An amount can be entered into either the run machine hours field or into the outside operations field in the Item Revision B record for an item. In either case, the entry is considered to be the base amount of the outside operation cost, not the hours. Therefore, the machine amount is never multiplied by a rate. Overhead also can be calculated and added to the outside operation cost amount. The value in the run labor field is not used to calculate outside operations cost.

Overhead code = A (Based on machine cost):

(A + B) x C

where: A = Setup machine cost B = Run machine amount as entered C = Overhead percent for code A

Overhead code = B (Based on labor cost):

(A + B) x C

where: A = Setup labor cost B = Outside operation amount (as entered) C = Overhead percent for code B

Overhead code = C (Based on machine hours per unit):

AxB

where: A = Setup hours B = Overhead rate for code C

Overhead code = D (Based on labor hours per unit):

AxB EPDM Concepts Guide Appendix B Page 97

where: A = Setup hours B = Overhead rate for code D

Source of data used in outside operations calculations

Routing file: Setup hours Run machine amount

Production Facility file: Overhead rate/percent

Outside operation cost calculations

Outside operation costs are calculated to be the sum of: Outside operation amount (as entered) Outside operation overhead (as calculated) Setup labor cost (as calculated) Run machine cost (as entered)

This value is put into the outside operation field in the Item Revision file. Setup machine cost is calculated and placed into the setup machine field in the Item Revision file, for overhead codes B, C, and D. For code A, the setup machine cost is added to the outside operation amount (as entered). Note: Efficiency is not used, nor is there any time basis code (TBC) adjustment for outside operations.

Cost roll-up logic

An items unit cost is the sum of the following fields contained in the Item Revision record: Current and Standard material this level Current and Standard outside operations this level Current and Standard purchase overhead this level Current and Standard setup labor this level Current and Standard run labor this level Current and Standard setup machine this level Current and Standard run machine this level Current and Standard manufacturing overhead this level

EPDM Concepts Guide Appendix B Page 98

The calculation of content this-level fields was discussed previously in Cost calculations. For purchased items, and items with item type code of 9, EPDM does not roll up costs. Cost roll-up is a technique to calculate the lower-level content fields and material this level for manufactured items whose item type code is other than 9. The technique is the same for both current and standard costs, differing only in that current cost fields are used to calculate current costs and standard cost fields are used to calculate standard costs. These fields are calculated as follows: Material this level = sum of materials this level of all direct, active components. Material lower levels = sum of materials this level and lower levels of all direct, active components. Labor lower levels = sum of labor contents this level and lower levels of all components. Overhead lower levels = sum of overhead contents this level and lower levels of all components.

Feature/options handling (includes discussion of phantoms)

A feature represents a way for an end-item (an item which has no parents) to define optional structures of itself. Lets use an example of an automobile (Z) as an end-item. One of Zs direct components is a feature called Engine (E). Es options are: 250 cc, 350 cc, 400 cc, and 450 cc. Another of Zs direct components is a feature called Color C. Cs options are: Blue, Red, Yellow, and Grey. The rest of Zs first-level components are subassemblies, purchased parts, fabricated items, raw materials, or phantoms. Only end-items can have features. End-items with features are prevented from being attached as components to higher assemblies. Features can be specified as required or non-required in the product structure relationship. A 2-digit feature can have up to 1295 options, depending on how the user lays out the Feature/Options Field Size Template (F/O template) in the EPDM questionnaire. End-items can have up to 20 features, depending on how many option field size questions the user answered during application tailoring. There is only one F/O template in EPDM (FOTAB1). The template has twenty elements, one position each. The only valid content of each element is a 0, 1, or 2. The F/O template is in a record in the SYSCTL file. Its key is FOTAB1. The F/O Template (an array) is used to overlay an S-number to locate which option was selected for which feature. The S-number is entered with an end-item when requesting an inquiry or a report. The S-number is a manually entered, non-stored field in which you can specify one option for each feature of the end-item wanted. To process an S-number, FOTAB1 is retrieved and then each option number is moved serially from the left of the S-number to a work array (20 elements, 2 characters each) for the lengths specified in FOTAB1. The features start at the left with feature 1 and go to the right sequentially.

EPDM Concepts Guide Appendix B Page 99

For example, if FOTAB1 = 11212 and item AX147 is a valid end-item with features, then for a product structure retrieval the following entries: Item AX147 S-number 9393107.

Translate to: Item AX147 with Feature 1s Option 9 Feature 2s Option 3 Feature 3s Option 93 Feature 4s Option 1 Feature 5s Option 07

Features vs. Phantoms

Features can never be stocked because they physically do not exist. A feature is a logical focal point that says here is a place to look for an associated set of options, only one of which may be used. Phantoms are not usually stocked. A phantom is a group of components that are used in many different products and are treated in each product as though they were listed individually in that products structure. In Inventory Management (if the phantom has a zero on hand balance) and in the single level mode with blow-through EPDM retrieval, when a phantom item is encountered, its components are retrieved and treated as though they were all present in the original single level bill of material. Features can be components only on the next lower level of an end-item. When product costing is run, costs are rolled up for phantoms as for any other assembly. However, since only one option at a time is possible for a feature, the features costs are a weighted average of all its options. This is done using the cost roll-up factor in each feature/option Product Structure record. Phantoms can be on any level in a product structure and can be in the structure of another phantom. EPDM supports phantoms on phantoms for 99 levels. Features have options which are selectively retrieved using S-numbers. Phantoms do not have options and therefore do not use S-numbers. Note: FOTAB1 is established during application tailoring, and is not maintained by application programs.

EPDM Concepts Guide Appendix B Page 100

Glossary

bill of material

A list of raw materials or components and the quantities needed to make an item, assembly, or end product. An option in offline EPDM that allows you to load bill of material information extracted from an AutoCAD (Computer Assisted Drawing) application to the EPDM database. A grouping in a set of related information about an object, called a card file A set of related information about an object. Each set contains groupings of related information, shown as a stack of tabbed index cards. Each group is a card. A file format produced when an Computer Assisted Drawing program extracts detail information from a CAD drawing.

CAD interface

card

card file

DXF file format

DXX file format

A file format produced when an Computer Assisted Drawing program extracts only bill of material information.

Enterprise Production Data Management

A MAPICS client server application for both single and multisite organizations that controls and manages production information.

fit

Characteristic that allows an item to connect to or become an integral part of another item.

form

The configuration of an item such as shape, size, density, weight, or other physical properties that identify the item.

function

The use or performance of an item.

item

Any raw material, manufactured or purchased part, subassembly, assembly, or end item. Identifies the choices you can make for which view, subset, sort, card file, or template you want to use with the current object: the last one you used, the default, or one you select

preferences

EPDM Concepts Guide Glossary Page 101

from a drop-down list. routing A sequence of operations required to make a manufactured item. A method of identifying the order the information about objects will appear in the list window. Sorts can be ascending or descending. A sort has its own unique name and can be public or private. A method of narrowing a list of objects to a smaller list in the list window. A subset has its own unique name and can be public or private A template is used to create a new object with a set of defaults. A template has its own unique name and can be public or private. When you preview a template, it looks like card file. A particular set of columns in a list window . A view has its own unique name and can be public or private.

sort

subset

templates

view

EPDM Concepts Guide Glossary Page 102

Index

activation of interface, 24 adjusted quantity per, 55 alternate bill of material, 44 AS/400 EPDM main menu, 61 AS/400 reports, 11 bill of material, 33, 43 CAD attributes, 65 CAD interface extract file, 63 CAD interface import drivers, 66 CAD interface program, 63 CAD interface translated files, 71 CAS printing record layouts, 76 cost generation, 60 cost simulation, 30, 60 costing enhancements, 55 costing overview, 11 cumulative yield, 55 currency, considerations for euros, 60 current costs, 59 data entry rules for offline maintenance, 77 default site, 20 effectivity dates, 46 engineering change history, 49 engineering release, 12 EPDM file relationships, 16 objects, 17 EPDM cost simulation, 60 EPDM default site, 20 euro currency considerations, 60 extract file, 63 facility, 26 file maintenance, 62, 73 file relationships, 16

generic routings, 42 header file for bill of material, 43 host printing, 11 import driver definition, 68 import drivers for CAD interface, 66 incoming files, 69 item, 33 item costing, 11 item definitions, 7 item mass update, 36 item process, 3, 9, 33, 46 item revisions, 7, 35 item status, 10 maintenance history, 49 manufacturing orders processing, 13 mass item update, 36 mass release to PDM, 52 migration, 20 offline EPDM, 61 offline maintenance, 62, 73 offline maintenance data entry rules, 77 operation yield, 55 PDM default site, 20 PDM migration of records to EPDM, 20 PDM to EPDM interface, 20 PDM to EPDM interface activation, 24 primary item process, 3 printing reports, 11 production site, 25 purchased items, 46 reason tracking, 49 reports, 11 rolling costs, 59 routing, 8, 33

EPDM Concepts Guide Index Page 103

routing header, 41 routing versions, 8, 40 simulation of costs, 30, 60 simulation site, 25 site copy, 50 site definition, 6 sites, 25 standard batch quantity, 55

standard costs, 59 status, 10 status codes, 36 translated files for the CAD interface, 71 versions for routings, 40 warehouses, 29 work center, 26 yield calculation, 55

EPDM Concepts Guide Index Page 104

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