Manufacturing#

The following features expand standard Microsoft Dynamics 365 Business Central¹ functionality to provide additional options to those working in your organization’s production department.

Manufacturing Setup#

The following table describes the "Production setup" extensions in KUMAVISION factory365 with links to the topics.

Further information can be found at: Manufacturing | Microsoft Learn

Comfort navigation for production bill of materials and routings#

This service area gives you direct navigation to the production bill of materials and routing from the parts card. This facilitates navigation to the production-related master data.

For further information see "comfort navigation for production bill of materials and routings “

For further information, see "Convenient navigation for production BOM and routings".

In KUMAVISION factory365, the insight via the Assist call has been extended so that it can also be called at the following places in the system:

• From the E+D order line to the production bill of materials, routing with its versions
• From the design monitoring line to the production bill of materials, routing with its versions
• From the MRP monitoring line to the production bill of materials, routing with its versions

Replace article in parts list Comfort#

Using the "Replace article parts list comfort" function, you have the possibility in KUMAVISION factory365 to consider only active versions for the replacement of an article / parts list via the field "Consider only active versions".

Retain operating cycle values#

In Microsoft Dynamics 365 Business Central¹ Standard, when the capacity unit (work center or work center group) is changed in the FA operation or the operation line in the operation description, individual values such as setup, transport or waiting times (work center “routing setup”) are also overwritten when the work center is changed.

However, as the description in the operation is the description of the activity to be performed, but existing default values are also simply changed when the capacity unit is changed, this behaviour can be prevented by activating the "Retain operation values" switch in the Manufacturing Setup.

To do this, call up the "Production setup" via the user search and make this setting.

When a new FA operation or operation line is created, both the description of the respective capacity unit and the default values for the "work centre" capacity unit are adopted.

Secondary operations#

General#

In Microsoft Dynamics 365 Business Central¹ it is possible to assign tools and personnel to an operation. However, these assignments are only managed by the system for information purposes.

Through the secondary operations in KUMAVISION Factory, it is possible to manage the capacity and costs of the tools as well as the personnel assignments.

The superior, leading operation (primary operation) defines the main process of an activity. All assigned personnel or tool assignments dependent on it are defined as secondary operations. These are linked to the primary operation via permanently assigned fields. Dates and quantities are managed in the primary operation and automatically derived into the secondary operations. This means that the secondary operations always run in parallel and within the start and finish times of the primary operation.

It is possible to edit the secondary operations, for example, to load an assistant only 50% of the time (to be loaded at the same time = 0.5) in the case of multiple machine occupancy.

Tool management#

With this extension of the operation tool table it is possible to manage and post specific tools for a machine in terms of capacity and costing. Tools can thus be managed as an independent capacity in production planning (by work center or work center group), as an article in warehouse, logistics and disposition, as an asset in the financial area or also as a cost object for controlling.

Detailed Personnel Planning#

The extension of the operation personnel table enables employee-specific operation and capacity planning and management per operation. It is recommended to plan at the work center group level and confirm or schedule at the employee work center level. Each employee is then set up as a work center and the work center group as a consolidated calendar.

Outlook Industry 4.0#

The management of additional production factors such as energy or CO² certificates will become increasingly important in the future in order to describe the accompanying processes of production more comprehensively and transparently. With secondary operations, an approach has been found that plans and manages these in a capacity-relevant manner.

Establishment#

Production facility#

First, call up the production setup via the user search. On the "General" info tab, the fields must be set up according to the following table for the secondary operations:

Work plan facility#

To set up the secondary operations, call up the desired routing via the item card. If you have not yet created a task list, create one first.

Then select the operation line. Via the menu selection "Work operation" you can assign these to the work operation via the selection "Tools" or "Personnel".

Tools#

Personal#

On the routing, the secondary operations can be displayed by clicking on the "Display secondary operations" item in the line menu.

The secondary operations are inserted, the operation number of which is composed of the primary operation + separator for personnel, tool + current operation number personnel, tool.

The line values of the primary operation are copied to the secondary ones and can be edited here.

If you enter a routing separately from an article, the secondary operations are set up in the same way.

Standard catalog codes forms secondary operations#

The attachment tables (-> secondary operations) for the operation can be preset by means of a standard catalog code (standard operation). As soon as a standard catalog code is inserted in the routing line, the operation attachment tables (tool, personnel, remarks, test specification) are updated.

This procedure can be used, for example, to preset tool sets as the standard catalog.

To set up a standard catalog, first call up "Standard catalogs" via the user search.

Via "New" in the menu ribbon you can create a new standard catalog under specification of a code and description.

Via the menu tab "Associated" > "Catalog" you have the possibility to assign tools / personnel to the standard catalog.

Then insert the standard catalog into a parallel routing on the desired line in the "Standard catalog" field. Secondary operations are created for the individual tools. Thus, capacity management and cost allocation can be tracked at the desired detail level for each individual tool.

Secondary operations in the production order#

Secondary operations can also be edited directly in a production order. The individual secondary operations can be edited and fine-tuned by production planning. It is important that the scheduling lies within the start-end dates of the primary operation.

Using the example of a firmly planned production order, you have to call up the routings via the "Line" call in the info tab of the same name.

Execute the "Show secondary operations" function in the ribbon under the "Start" menu tab to display the secondary operations.

Deleting / inserting a secondary operation#

To delete a secondary operation or add another one, first select the line of the primary operation.

Then select the "Tools" or "Personnel" menu item under "Associated" in the ribbon.

The Tools / Personal Edit card opens, where you can insert a secondary operation via "New" or delete an existing one via "Delete". Confirm your change with "OK".

Editing a secondary operation#

If the capacity of a secondary operation is to accompany the process with a certain percentage, proceed as follows:

Change the field: "Simultaneously debit and debit the processing time with equal proportions.

As a result, the cycle time of the operation is maintained within the start-finish time of the primary operation, the Erw. capacity requirement is reduced and the target operation costs are reduced to the percentage share.

Overproduction#

With this functionality you can define which deviation of the target production quantities you want to allow in percentage.

To do this, call up the production setup via the user search. On the "General" info tab, activate the "Check overproduction" check box.

On the item card, you can then define the desired percentage of overproduction on the "Procurement" info tab in the "Overproduction %" field.

When this function is activated in the production setup, the system checks the Overproduction % field on the item card to see if the quantity completed is greater than the Maximum overproduction quantity. If this is the case, an error message appears.

Example With an FA quantity of 1000, a maximum overproduction quantity of 20% = 200 is calculated. This results in a tolerance quantity of 1000..1200 and from 1201 an error message of the finished quantity appears.

Capacity quantities in FA Overview#

The following status fields have been added to the FA overviews:

• Allocated capacity requirements
• Actual time (according to workstation group filter)
• Remaining time (as the difference between the two fields)

These fields are in the overviews:

• Releasing production orders (Microsoft Dynamics 365 Business Central¹ Standard)
• Releasing E+D order
• Releasing E+D order (costing)

Traffic light entries#

The availability traffic light in KUMAVISION factory365 extends the production order of Microsoft Dynamics 365 Business Central¹ with the visualization of MRP and capacity availability.

These are available in the overviews of the production orders and in the production order lines ("MRP availability" and "Capacitive availability") as well as in the FA components (only "MRP availability") and the FA routing (only "Capacitive availability") in the status: Planned, Firmly planned and Released.

The "Calculate availability traffic light" function is available in the above overviews to determine the planning and capacity availability.

Setup#

Traffic light assignment setups#

Before you can use the availability traffic light, you must store the symbols required for visualization.

The "Availability traffic light setup" facility is available for this purpose.

Call up the "Availability traffic light setup" via the user search. Use "New" in the ribbon to create a data record for each option value and store the required symbol (image).

Threshold values (minimum threshold %) and (maximum threshold %)#

Threshold values "Capacity (min.) %" and "Capacity (max.) %" can be stored hierarchically at the workstation, the workstation group and/or the department.

To do this, call up the "Workstations" or "Workstation group" via the user search and open the respective card.

You can store the threshold values "Capacity (min.) %" and "Capacity (max.) %" on the "Traffic light control" information tab.

To store the threshold values "Capacity (min.) %" and "Capacity (max.) %" in the department, call up the "Departments" via the user search and select "Edit list".

Further information can be found under: Set up workstations and workstation groups.

Traffic light entries dispositiv#

Grundlage zur Ermittlung der dispositiven Verfügbarkeit sind die Artikel-"Verfügbarkeit nach Ereignis" und die "Reservierungen".

Die Artikel-"Verfügbarkeit nach Ereignis" wurde um das Feld "Restbestandsmenge" erweitert, welches die Artikelverfügbarkeit - ohne geplante Zugänge angibt. Die Menge beinhaltet alle Bedarfe, jedoch nicht den voraussichtlichen Zugang und wird zur nachfolgenden Definition herangezogen.

Baugruppen erben das jeweils "schlechteste" Komponenten – Ergebnis.

The definition of the "MRP availability traffic light" is as follows:

Option	Description	Definition of	Traffic light symbol Example*
Empty	not calculated
Green	Reservation against stock	Reservation against article items
Green	sufficiently available on date (in stock)	Availability balance: positive or results in 0 Remaining stock: positive or results in 0
Yellow	Reservation against receipt	Reservation against order or relocation
Yellow	Sufficiently available on date (by receipt)	Availability balance: positive or results in 0 Remaining stock: negative
Warning	Reservation against receipt with reservation conflict	Reservation against order or stock transfer with reservation conflict
Red	not available on date	Availability balance: negative

Traffic light entries capacitive#

"without" thresholds#

The basis for determining the capacitive availability is the "capacity" based on the calendar items compared to the "allocated capacity (FA capacity requirement)".

Assemblies inherit the "worst" component result!

The definition of the "Capacitive availability traffic light" without setting up threshold values is as follows:

Option	Description "without threshold values"	Traffic light symbol Example*
Empty	not calculated
Green	"Allocated capacity" is less than or equal to the "Capacity"
Red	"Allocated capacity" is greater than "Capacity"

"with" threshold values#

The basis for determining the capacity availability is the "Capacity (min.)" and "Capacity (max.)", which are calculated using the "Capacity" based on the calendar items and the threshold values "Capacity (min.) %" and "Capacity (max.) %" stored at the department, work center group or work center, compared to the "Assigned capacity (FA capacity requirement)".

The calculation is made with the "Calculate availability traffic light" as follows:

Assemblies inherit the "worse" component result.

The definition of the "Capacitive availability traffic light" with the establishment of threshold values is defined as follows:

Option	Description "with threshold value"	Traffic light symbol Example*
Empty	not calculated
Green	"Allocated capacity" is less than the "Capacity (min.)"
Yellow	"Allocated capacity" is equal to or greater than the "Capacity (min.)" and less than or equal to the "Capacity (max.)"
Red	"Allocated capacity" is greater than the "Capacity (max.)"

Automatic article tracking upon release of the FA#

By means of the functionality "Automatic article tracking when FA is released" the steps:

• Manually open the article tracing
• Calling the function for determining the serial number from the item-specific number series
• Closing the mask: Article tracing
• Repeat steps per actual message line determined automatically.

Triggers for automatic generation of item tracking are:

• Status change to Released FA, item tracking lines are created
• Update production order" function
• Erect the FA from planning proposal
• Establish the FA from sales order

Establishment#

Article card#

The items with stored item tracking can be set up for automatic assignment in the "Item tracking" info tab via the "Set up production autom. item tracking" field.

Article pursuits#

Item tracking is set up using the Microsoft Dynamics 365 Business Central¹ Standard.

Number assignment for automatic article tracking#

The automatic assignment of the article tracking is only valid for "actual messages of production" and not for consumption messages. Thus, this assignment only affects output-side usage in the Production application area. Serial numbers If only serial numbers are ticked, an automatic generation of n item tracking line and quantity 1 will take place. Batch numbers If only batch numbers are checked, an automatic generation of an article tracking line with 1 batch and corresponding quantity will take place. Serial and batch numbers If both fields of the item tracking code are checked, n item tracking lines are created with serial numbers and quantity 1 and always the same batch numbers for all quantity = 1.

Procedure#

The automatic generation of the article tracking lines takes place for all FA lines of the production order for which an automatic creation is set in the article. It is always filled up to the maximum possible FA line quantity.

It applies: n lines with serial number and quantity 1, or 1 line with batch number and quantity=maximum possible quantity or combination of both).

The user can manually change these automatically generated item tracking lines afterwards (if desired).

A new execution of one of the above events (e.g. a status change of the FA) will take into account any article tracking lines that have already been created, regardless of whether they were previously created manually or automatically. Then, if necessary, article tracking lines will be created automatically only up to the difference to the maximum possible quantity.

Example:
The FA was created in Planned status. The FA line has the quantity 7 and an article with automatic serial number generation for status Fixed Planned. In the Planned status, the user already manually enters 4 serial numbers for the FA line. After that, the user will change the status of the FA to Fixed Planned. The application will generate only the 3 missing serial numbers for the FA line.

Optimized absenteeism management#

For the recording of absences from machines for maintenance / repairs etc., the Microsoft Dynamics 365 Business Central¹ process requires that you first register the absences, then transfer the registered absences as absenteeism items and update the calendar afterwards.

In KUMAVISION factory365, this process has been optimized so that the individual steps can be executed directly when the function is called. To maintain the absence times in KUMAVISION factory365, proceed as follows:

Call up the "Logged absences" via the user search.

Via the menu items "Reasonable. Absence time (workstation)" or "Appropriate absence time (workgroup)" in the menu ribbon. Absence time (work group) in the menu ribbon, you can enter the absence times for a work center or for a work group.

The entry screen opens, where you can enter the absences using the table below.

Confirm your entry with "OK". If the "Apply" and "Update calendar" fields have been activated, the registered absences have automatically been adopted as absence items and the calendar updated accordingly.

Shipping units#

When manufacturing complex articles, the situation can arise in shipping that the manufactured article must be broken down again into so-called shipping units that can be sensibly transported. In order to be able to map this process in Microsoft Dynamics 365 Business Central¹, this scope of services supports shipping units in manufacturing and logistics.

The shipping units can currently cover three different scenarios, which are described below.

Establishment#

Design & development facility#

In the Design & Development setup, you have the option of using the "Use shipping units for logistical structure explosion" switch on the "Execution" info tab to control whether you want to visually display the logistical structure explosion divided into the corresponding shipping units in an E+D order. For this option you activate this switch. In the E+D order, the option "logistical" can then be selected in the process for the visualized representation via the "Structure resolution" field.

Shipping units#

Via the "Shipping units" you can define them in general by assigning a code (abbreviation) and an associated description.

Assignment in the master data#

Shipping units can already be preassigned in the planning phase. For this purpose, a shipping unit code can be entered in the lines of the production bills of material. This code does not yet have a fixed reference to a production order. When a production order is created, this shipping unit code is transferred.

Assignment in process#

If there is an existing production order, shipping units can be assigned in the components. This can be done in the component lines as well as in released and finished E+D orders in the lines. In addition, the project module has also been integrated so that the assignment from the project structure Project structure out of the project. For this purpose, the fields "Shipping unit code", "Project-specific shipping unit", "Component as shipping unit" and "Transfer quantity to shipping unit" can be displayed in the respective screens.

Relocation of components#

Components combined to form a higher-level shipping unit#

A production order is set up whose components are to be transferred to a production warehouse for assembly. The components are grouped into shipping units that are easy to transport. From a released (and a completed) E+D order, these components can be inserted into a stock transfer order.

To do this, first select the desired lines and then execute the "Transfer selected shipping units" function via Lines > Function.

It is checked that the components to be transferred have already been consumed. If the correspondingly marked components have been consumed, then a stock transfer order is created, which transfers the shipping units from the component storage location to the FA storage location. The information from the transfer route is used for the "In Transit Code". In the FA shipping units list you can now see that the "Quantity in Outbound Document" is changed.

In the drilldown the corresponding shipping unit item is displayed and via the function "Display document" it is possible to switch to the corresponding document. If the storage locations are subject to goods issue or goods receipt, these can be created and posted according to the standard.

No new item items are created in the background because the components have already been consumed. New shipping unit items are created by the postings. Via these, the status can be checked from the shipping unit overview (opens by the lookup on a shipping unit). After posting the receipt, the order is completed. The shipping unit can now no longer be shipped, as it has already delivered the complete quantity.

Shipping individual components as a shipping unit#

It may be necessary to create suitable logistics documents for the customer or the transport, for individual components of a production order. With the "Component as shipping unit" identifier in the E+D order lines (and the Project structure) you have the possibility to define a shipping unit that is specific for a single component in the production order. If the check mark is set, a shipping unit is automatically created that has the item number of the component as the shipping unit code and corresponds to the FA component line in terms of quantity, unit and description.

The "Transfer quantity to shipping unit" field can be used to control whether only a partial transfer of the component is to take place. The field is preset with the quantity available for stock transfer. This is the difference between the posted quantity and the quantities that are already in shipping or have been shipped. Therefore, it is necessary that at least the quantity of the component to be shipped is posted as consumption.

If the stock transfer is to take place, you can enter the corresponding lines in the E+D order or the Project structure and transfer them to a stock transfer order using the "Transfer selected shipping units" function. The rest of the procedure is the same as that described in the section "Components combined to form a higher-level shipping unit".

Shipping units in sales#

If a production item is sold, the shipping units stored in the production order can also be inserted in a goods issue that was created from a sales order. For this purpose, the function "Insert shipping units" can be used in the goods issue.

If the sales line was reserved on a corresponding item line, then the shipping units from this production order will be automatically inserted. If there is no reservation, a selection of items is opened and the user can decide which item should be sold. After selection, the shipping units belonging to the item are inserted into the goods issue.

If the production order belonging to the item is not yet finished, the user must confirm that he wants to continue.

The original line remains, but the quantities are removed, since this item is automatically posted in the background after posting the shipping units. The posting of the goods issue with shipping units is now done as in the standard. After complete posting, the original item is also delivered and can be invoiced.

Project-specific or cross-FA shipping units#

In connection with the plant engineering solution, it is also possible to use shipping units across FAs within a project. For more information, see Shipping preparation.

Shipping units item#

When inserting a shipping unit into a document, items are written. These can have 4 statuses:

• Outbound (Shipment): a stock transfer was created or a goods issue was created from a sales order without anything being posted.
• In Transit: The goods have left the warehouse but have not yet arrived, i.e. the goods issue has been posted but the goods receipt has not.
• Receipt: The receipt of the goods has been recorded, but not yet booked.
• Delivered: The goods have been delivered completely. The items are used to track the quantities in the shipping units overview, even if the posted documents should already be deleted.