Walkthrough: Work with Families

This walkthrough describes how to create families, plan for production using families, and process family production orders.

Story

The JF Company purchases cases of beef, which then must be cut into different portions before selling to customers. One case of beef may produce different cuts of meat depending on how the meat is butchered as well as waste products.

JustFood receives a case of BEEF EX RIB 2PC (FAM-RAW-00001), which is expected to weigh 33.4 pounds, and when it is butchered, it can produce one of following combinations:

| Combination | Beef Rib Roast-1 Bone (FAM-FG-00001) | Beef RIB Roast-2 Bone (FAM-FG-00002) | Beef RIB Roast-3 Bone (FAM-FG-00003) | Beef Rib Steak (FAM-FG-00010) | Beef Trim (FAM-WIP-00001) | Waste

(FAM-WIP-00002)
Combination 1
Combination 2
Combination 3
Combination 4
Combination 5

These combinations will be made into families.

Several customers have placed orders for the following family items:

• Beef Rib Roast-1 Bone (FAM-FG-00001)
• Beef Rib Roast-2 Bone (FAM-FG-00002)
• Beef Rib Roast-3 Bone (FAM-FG-00003)
• Beef Rib Steak (FAM-FG-00010)

The JF company must calculate what combination of beef cases must be consumed to meet the demand of the customers. After the planning is completed, the production orders can be created and finished for the production orders.

Prerequisites

• Items were set up to be used with families. To set up the required items, see the Create Family Items Walkthrough.

Setting up the Overage Percentage

You must define the family planning overage percentage. When you've calculated the family planning, on the Family Production Worksheet page, the Family Overages FactBox displays the overages that exceed the defined overage percentage.

To set up the overage percentage

1. Choose , enter manufacturing setup, and then choose the related link.

   The Manufacturing Setup page opens.

2. On the Family Production FastTab, in the Family Prod. Planning Overage % field, enter the percentage that represents when an overage is displayed on the Family Production Worksheet page, on the Family Overages FactBox.

   In this example, any overages over 10 percent will be displayed on the Family Production Worksheet page, on the Family Overages FactBox.

Creating a Family Group

To group similar families together, you can create family groups.

The JF Company will create the BEEF RIB family group.

To create a family group

1. Choose , enter family groups, and then choose the related link.

   The Family Groups page opens.

2. On the action bar, choose New.

3. In the Code field, enter the code that represents the family group, for example, BEEF RIB.

4. In the Description field, enter the description of the family group.

Creating a Family Bill of Materials

When creating a family, a bill of materials (BOM) will be applied to the family header, which will be known as the family BOM. The family BOM includes the one or more items that will be consumed to produce the items in the family.

The FAM-BEEF-RIBEYE family BOM must be created, which will include the BEEF EX RIB 2PC (FAM-RAW-00001) item.

To create a family bill of materials

1. Choose , enter production boms, and then choose the related link.

   The Production BOMs page opens.

2. On the action bar, choose New.

   The Production BOM page opens.

3. On the General FastTab, perform the following steps:

   1. In the No. field, enter the number for the production BOM, for example, FAM-BEEF-RIBEYE.

   2. In the Description field, enter a description of the production BOM, for example, BEEF EX RIB 2PC.

   3. In the Unit of Measure Code field, select the parent item’s unit of measure code, for example, CS.

4. To add the parent family item to the Lines, perform the following steps:

   1. In the Type field, select Item.

   2. In the No. field, select the item that will be consumed to produce the items in the family, for example, FAM-RAW-00001.

   3. In the Quantity Per field, enter how many items must be consumed to produce the items in the family. In this example, 1 case will be consumed.

5. On the General FastTab, in the Status field, select Certified.

Creating a Family

A family must be created, which will include which item is to be consumed, what items will be produced, and how the costs will be distributed.

Because the BEEF EX RIB 2PC (FAM-RAW-00001) item can produce five different combinations when it is consumed, five families must be created.

The following families will be created:

• BEEF-RIBEYE
• BEEF-RIBEYE-A
• BEEF-RIBEYE-B
• BEEF-RIBEYE-C
• BEEF-RIBEYE-D

If an item is expected to be sold, for the item to be considered during planning, it is recommended that the item be set as a Primary output type.

This example will demonstrate how to set up the BEEF-RIBEYE family.

To create a family

1. Choose , enter families, and then choose the related link.

   The Families page opens.

2. On the action bar, choose New.

   The Family page opens.

3. On the General FastTab, perform the following steps:

   1. In the No. field, enter RIBEYE.

      If families share the same family BOM, you may want to keep the family numbers similar, for example, BEEF-RIBEYE, BEEF-RIBEYE-A, BEEF-RIBEYE-B and so on.

   2. In the Description field, enter BEEF RIB RIBEYE-1 BONE.

   3. In the Family Group Code field, select BEEF RIB.

   4. In the Family BOM No. field, select FAM-BEEF-RIBEYE.

      This BOM contains the item that will be consumed to produce the family line items. Note: The BOM must be certified.

   5. In the Routing No. field, select FAM-FG-00001.

      If a routing number was not added to a line, the routing number from the header will be pushed to the production order for the line.

4. On the Lines, add the family items that will be produced when the family BOM item is consumed.

   For this family, when the BEEF EX RIB 2PC (FAM-RAW-00001) item is consumed, it will produce 22 pounds of Beef Rib Roast-1 Bone (FAM-FG-00001), 5 pounds of Beef Rib Steak (FAM-FG-00010), 3.9 pounds of Beef Trim (FAM-WIP-00001) and 2.5 pounds of Waste (FAM-WIP-00002).

   Add the following lines:

   Item No.	Output Type	Family BOM Cost Dist. %	Planning Order	Alternate Quantity	Alternate Unit of Measure
   FAM-FG-00001	Primary	78	10	22	LB
   FAM-FG-00010	Secondary	19		5	LB
   FAM-WIP-00001	Other	3		3.9	LB
   FAM-WIP-00002	Other	2.5			LB

   The Production BOM No. and Routing No. fields pulled in the values from the selected item.

   Values were entered in the Alternate fields to allow the weight measurement to be used. The Quantity and Quantity (Std. Weight UOM) were updated accordingly.

   The FAM-FG-00001 item has an output type of Primary, which means the item will be considered when calculating family planning from the Planning Worksheet page. The planning order is 10, which will be considered during planning when the FAM-FG-00001 item is part of another family.

   For the Output Type field, Primary items will be considered when calculating family planning from the Planning Worksheet page. If a primary item is included in more than one family, a unique value must be entered in the Planning Order field. During planning, the item with the lowest planning number will be given priority over the same item in a different family. The value must be unique for each item that is in a different family as a primary.

   The Family BOM Cost Dist. % field displays how the costs of the family BOM will be distributed across the family line items. The cost distributions will be pushed to production orders, and must equal 100 before a production order can be finished.

5. Change the Status field to Certified.

   JustFood checks that all of the BOMs and routings are certified, and that the Planning Order field has a unique value for items that are primary in more than one family.

6. To add the remaining families, enter the details that are shown below:

   BEEF-RIBEYE-A

   On the General FastTab, enter the following details:

   • No.: BEEF-RIBEYE-A

   • Description: BEEF RIB RIBEYE-2 BONE

   • Status: Certified

   • Family Group Code: BEEF-RIB

   • Family BOM No./Active Version: FAM-BEEF-RIBEYE

   • Routing No./Active Version: FAM-FG-00002

   On the Lines, enter the following details:

   Item No.	Output Type	Family BOM Cost Dist. %	Planning Order	Alternate Quantity	Alternate Unit of Measure Code
   FAM-FG-00002	Primary	78.00	10	22	LB
   FAM-FG-00010	Secondary	19.00	0	5	LB
   FAM-WIP-00001	Other	3	0	3.9	LB
   FAM-WIP-00002	Other	0	0	2.5	LB

   BEEF-RIBEYE-B

   On the General FastTab, enter the following details:

   • No.: BEEF-RIBEYE-B

   • Description: BEEF RIB RIBEYE-3 BONE

   • Status: Certified

   • Family Group Code: BEEF-RIB

   • Family BOM No./Active Version: FAM-BEEF-RIBEYE

   • Routing No./Active Version: FAM-FG-00003

   On the Lines, enter the following details:

   Item No.	Output Type	Family BOM Cost Dist. %	Planning Order	Alternate Quantity	Alternate Unit of Measure Code
   FAM-FG-00003	Primary	78.00	10	22	LB
   FAM-FG-00010	Secondary	19.00	0	5	LB
   FAM-WIP-00001	Other	3	0	3.9	LB
   FAM-WIP-00002	Other	0	0	2.5	LB

   BEEF-RIBEYE-C

   On the General FastTab, enter the following details:

   • No.: BEEF-RIBEYE-C

   • Description: BEEF RIB RIBEYE-STEAKS

   • Status: Certified

   • Family Group Code: BEEF-RIB

   • Family BOM No./Active Version: FAM-BEEF-RIBEYE

   • Routing No./Active Version: FAM-FG-00001

   On the Lines, enter the following details:

   Item No.	Output Type	Family BOM Cost Dist. %	Planning Order	Alternate Quantity	Alternate Unit of Measure Code
   FAM-FG-00010	Primary	97.00	10	27	LB
   FAM-WIP-00001	Other	3	0	3.9	LB
   FAM-WIP-00002	Other	0	0	2.5	LB

   BEEF-RIBEYE-D

   On the General FastTab, enter the following details:

   • No.: BEEF-RIBEYE-D

   • Description: BEEF RIB RIBEYE-1/2 BONE

   • Status: Certified

   • Family Group Code: BEEF-RIB

   • Family BOM No./Active Version: FAM-BEEF-RIBEYE

   On the Lines, enter the following details:

   Item No.	Output Type	Family BOM Cost Dist. %	Planning Order	Alternate Quantity	Alternate Unit of Measure Code
   FAM-FG-00001	Primary	39.00	20	12	LB
   FAM-FG-00002	Secondary	39.00	0	12	LB
   FAM-FG-00010	Secondary	19.00	0	3	LB
   FAM-WIP-00001	Other	3	0	3.9	LB
   FAM-WIP-00002	Other	0	0	2.5	LB

Calculating Family Planning

Customers have ordered a range of beef items, and the JF Company must plan production around these orders.

The following items have been ordered for July 17, 2018:

• 66 CS Beef Rib Roast-1 Bone (FAM-FG-00001)
• 77 CS Beef Rib Roast-2 Bone (FAM-FG-00002)
• 76 CS Beef Rib Roast-3 Bone (FAM-FG-00003)
• 40 CS Beef Rib Steak (FAM-FG-00010)

Because all the items are part of families, to determine what family items must be consumed to meet the demand, you can run the planning calculation.

Prerequisites for Calculating Family Planning

• Sales orders were created for the following items:

  • 66 CS Beef Rib Roast-1 Bone (FAM-FG-00001)
  • 77 CS Beef Rib Roast-2 Bone (FAM-FG-00002)
  • 76 CS Beef Rib Roast-3 Bone (FAM-FG-00003)
  • 40 CS Beef Rib Steak (FAM-FG-00010)

To populate the planning worksheet

1. Choose , enter planning worksheets, and then choose the related link.

   The Planning Worksheets page opens.

2. On the action bar, to open the Calculate Plan - Plan. Wksh. page, choose Process > Calculate Regenerative Plan.

   The Calculate Plan - Plan. Wksh. page opens.

3. In the Options section, perform the following steps:

   1. Turn on MPS.

   2. Ensure that MRP is turned off.

      Materials Requirement Plan (MRP) calculations are not considered by family planning.

   3. In the Starting Date field, enter the date to start evaluating inventory availability, for example 7/17/2018.

   4. In the Ending Date field, enter the date after which demand and supply are not considered, for example, 7/31/2018.

4. In the Items section, perform the following steps:

   1. In the Show results section, in the Where field, select Replenishment System, and then in the is field, select Prod. Order.

   2. In the Limit totals to section, in the And field, ensure that Location Filter is selected, and then in the is field, select SEATTLE.

5. Choose OK.

   The planning worksheet is populated with the planning lines.

   At this point, none of the Family fields are populated.

To calculate family planning

1. Choose , enter planning worksheets, and then choose the related link.

   The Planning Worksheets page opens.

2. On the action bar, choose Navigate > Family Production Worksheet.

   The Family Production Worksheet page opens.

3. On the action bar, choose Process > Calc. Family Production Plan.

   The Calculate Family Prod. Plan page opens.

4. In the Location Code field, select DETROIT.

   The calculation will only look at records on the Planning Worksheet for the selected location.

5. In the Date field, enter 6/21/2016.

   The calculation will only look at records on the Planning Worksheet for the selected date.

6. Choose OK.

   The families that meet demand are returned. Only family component items with an Output Type of Primary are considered in the planning.

   The Family Factor field displays how many of the families must be produced, and the ,Quantity field displays how much of each item will be produced. The demand for the BEEF RIB STEAK (FAM-FG-000010) item is filled through the production of several families because it is produced as a secondary component.

   Each item has an overage, but only the FAM-FG-000010 item is listed on the Family Overages FactBox because it's overage is more than 10 percent, as defined on the Manufacturing Setup page.

   If you return to the Planning Worksheet, you can see that it now displays which lines have been planned from the Family Production Worksheet page.

To adjust the families

Because the BEEF RIB STEAK has an overage of more than 10%, the families must be adjusted to reduce that overage. After the plan has the desired values, you can create the production orders.

1. From the Family Production Worksheet page, select the BEEF-RIBEYE family, and then on the action bar, choose Process > Delete Family.

   The selected family is deleted.

   The Family Shortages now displays that there is a shortage for the FAM-FG-00001 item.

2. On the action bar, choose Process > Add Family.

   The Family Selection page opens.

3. In the Family No. field, select BEEF-RIBEYE-D.

4. In the Family Factor field, enter 13.

5. Choose OK.

6. For the BEEF-RIBEYE-A family, change the family factor to 26.

   The FAM-FG-000010 item still has an overage, but it's less than the original plan, and there is less trim and waste.

To create the production orders

1. From the Family Planning Worksheet page, on the action bar, choose Process > Accept Plan.

   This selects the Accept Action check boxes and you can no longer make any more changes.

2. On the action bar, choose Process > Carry Out Action Message.

3. In the Production Order field, select Planned.

4. Choose OK.

   The action is carried out successfully, and the records are removed from the Family Production Worksheet page and the Planning Worksheet page. The planned production orders are created.

Processing a Family Production Order

The planned production orders were changed to released production orders, and the picks were registered. The production order is ready to be processed.

1. Choose , enter released production orders, and then choose the related link.

   The Released Production Orders page opens.

2. Select the released production order that was created for the family, and then on the action bar, choose Manage > View.

3. On the Lines section, select the first blank line.

   This allows all lines to be displayed in the Production Journal.

4. On the Lines section action bar, choose Line > Production Journal.

   The Production Journal page opens.

   The blue line indicates that the item is from the family header BOM. The consumption lines have been filled through the registered pick.

5. To post the consumption and output, perform the following steps:

   1. To enter the item tracking for the FAM-FG-00001 item, select the last operation for the FAM-FG-00001 item, which is operation number 20.

   2. In the Output Quantity field, enter the output quantity.

   3. On the action bar, choose Navigate > Line > Item Tracking Lines.

   4. In the Lot No. field, enter the lot number.

   5. In the Expiration Date field, enter the expiration date.

   6. In the Quantity (Source UOM) field, enter the quantity to output.

   7. In the Net Weight field, enter the net weight.

   8. Choose Close.

      Enter the item tracking for the remaining lines.

   9. On the action bar, choose Process > Post.

6. Adjust the family cost distribution so that it's distributed by weight.

   By default, the production order pulls the value in the Family BOM Cost Dist. % field from the family.

   Note

   The Unit Cost value reflects the unit cost defined for the item, and is not related to the costs that will be distributed based on the family BOM costs.

   To adjust the family cost distribution so that the cost is distributed by weight, perform the following steps:

   1. On the Released Production Order page, on the action bar, choose Process > Calc. Family BOM Cost Dist. %.

      The Calc. Family BOM Cost Dist. % page opens.

   2. In the Calculate Distribution By field, select Std. Weight UOM, and then choose OK.

      The values in the Family BOM Cost Dist. % field are updated.

      The total net weight of the consumed family BOM was 434.2 LBS. For the FAM-FG-00001 item, the produced weight was 154 LBS which is 35.46753% of the consumed item.

      The Family BOM Cost Dist. % field must total 100 before the production order can be finished.

7. On the action bar, choose Process > Change Status.

8. Select Finished, and then choose Yes.

   The released production order is changed to a finished production order.

   When you open the Item Ledger Entries page for the finished production order, you can see how the costs were distributed. The total cost of the family BOM that was consumed was $7150.00, which was then distributed based on the Family BOM Cost Dist. % that was defined on the production order.

   For example, the cost distribution for the FAM-FG-00001 item was 35.46753% of $7150.00, which is $2535.93. Because the FAM-FG-00001 item also consumed the JFP-F-BAGSHRINK item, $23.00 was added to the cost of the FAM-FG-00001 item, which gives the actual cost of $2535.93 for the item.

   The cost distribution for the FAM-FG-00002 item was 36.38876% of $7150.00, which is $2601.80.

See Also

About Families

About JustFood Walkthroughs