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ERP Tips: Using work orders to backflush

Pipe-and-plumbingPhoto by Samuel Sianipar on Unsplash

MANMAN still runs operations at companies around the world. Not a lot of companies, of course. It's 2019 and everything is smaller in size, not just your hearing aids. The MANMAN managers are still looking for tips. Here's one generated from a question out of the Altra Industrial Motion Corp. from senior systems analyst James English.

We are on MANMAN version 9.1 on an HP 3000. We have all MANMAN modules, including MANMAN/Repetitive. Is it possible to backflush work orders without using Repetitive? Our one manufacturing location is looking at simplifying work order transactions. They are manually transacting each operation on their work orders, even though they don’t collect actual hours.

Short question: How can they use work orders instead of using Repetitive?

When a work order has been received into stock, it comes to the scheduler-planner to push the times through each sequence, since the operation no longer does time cards. Once that time-pushing is done, the work orders are closed for material and labor. Once a work order is received into FG, instead of pushing the time through each operation, could we just back flush?

Alice West of Aware Consulting says

You can set all the components on your bill as “consumable” and then when you complete the WO the system will consume all the materials.  We always called this feature “poor man’s Repetitive.” 

However, it sounds like you are trying to simplify the labor portion of the transaction.  For that, you can look at your COMIN variable settings. Here is a chart I put together to show how 3 different variables work together.

MANMAN backflush

So to combine the operation movements with the movement to stores, you probably want to set your COMIN variables as follows:

93 to 0

121 to 1

177 to 1

You can also put all the hours on the routing onto the last operation and then only transact that one sequence.  In order to earn the correct labor cost you only need to transact the sequences that have standard labor hours.  One reason users transact every step is to get an operation status, but since you’re transacting the movements after the fact you clearly don’t need that.

Terry Floyd of The Support Group also says

I wrote a mod years ago that is/was installed at several MANMAN/MPE sites.  I called it TR 3-eightly-thru (because it was originally from TR302 and does a “move-thru”).  It’s a bunch of code down inside subroutines under GENTRS; when it prompts Next Sequence and you enter the last Operation Sequence (or any Operation Sequence out of order) it prompts “Move Thru?” and if you answer YES, it performs all of the moves through the subsequent sequences as if you had done them one at a time.

So, instead of changing all of your routings (that might be a lot of work), you could use this version of TR302, do a lot less data entry, and still earn standard labor dollars.  I still have this code for Releases 9 and 11, Jim, but it’s not a Standalone and requires re-linking all of SYSMAN.  I could probably turn it into a Standalone and make it a lot easier to install.