Intended learning outcomes: Present the concept of master data. Explain the production order as a collection of master data. Describe a simple product structure.
Master data are created as the result of product and process design that is not associated with a specific customer order. A suitable customer, production, or procurement order can then be repeatedly derived from these master data if an order quantity and date are added to the product and process description.
This can be compared to a recipe in a cookbook since the recipe is developed on its own, that is, independently of the subsequent cooking processes. Such a recipe may be used repeatedly for preparing meals, and different order quantities (= number of people) may be applied. The cook book contains the following information:
- The ingredients are shown in a list (recipe).
- The sequence of individual working tasks is also given in the form of a list that describes how to arrive at the result; that is, the finished meal, starting from the ingredients.
- The cooking utensils, such as knives, pans, and so forth, are mentioned in the description of the work. They are sometimes also summarized in a list.
- The cooking device required, for example, stove, oven, sink, is mentioned in the description of the work.
The same concept can be applied to the description of the product and production process within a company, using generalized or specific terminology:
- The result is a product or a parent item.
- The ingredients become components and the recipe becomes a bill of material.
- The work becomes operations and the sequence of operations becomes a routing sheet or process plan.
- The cooking device and other cooking utensils become machinery and other production equipment.
- The actual kitchen becomes a work center with one or more workstations at which the individual operations are carried out.
Figure 17.2.1.1 shows, by way of example, the composition of master data in the form of a production order of the ball bearing of Figure 16.2.1.1. It specifies an order quantity (a lot) of 100 units of measurement (in this case “piece”). No dates are specified, however. The only other information is certain characteristic data and positions. [note 1701]
Fig. 17.2.1.1 The production order as a collection of master data.
- The ball bearing product (item ID 83569) is a potential item receipt and consists of the two components ring (item ID 83593, an in-house made semifinished good) and Uniflon (item ID 83607, a purchased raw material). The bill of material for the product thus has at least the two specified positions. These are potential item issues.
- The ball bearing (item ID 83569) is produced by the two operations Cut Uniflon (position 250 at work center ID 907501, “Manual production”) and Press together (position 270 at work center ID 908301, “Special presses”). The routing sheet for the product thus has at least the two specified operations. These are the potential work order positions (or order operations).
Figure 17.2.1.2 shows the simple, single-level convergent product structure that occurs in the initial stages. See also Figures 17.1.2.1 and 1.2.2.2. All the resources needed to manufacture the product are listed as positions in the product structure. Such a position may thus be a component, an operation, or production equipment.
Fig. 17.2.1.2 A simple product structure.
Continuation in next subsection (17.2.1b).
Course section 17.2: Subsections and their intended learning outcomes
17.2 The Master Data for Products and Processes
Intended learning outcomes: Describe master data of products, components, and operations. Explain the data structure of item master, bill of material, and where-used list. Disclose the data structure of work center master data, the work center hierarchy, as well as for operation, routing sheet, production equipment, bill of production equipment, and bill of tools.
17.2.1 Product, Product Structure, Components, and Operations
Intended learning outcomes: Present the concept of master data. Explain the production order as a collection of master data. Describe a simple product structure.
17.2.1b The Intermediate Part
Intended learning outcomes: Identify the intermediate part used simultaneously as a component in higher-level products.
17.2.2 Item Master Data
Intended learning outcomes: Present the concept of the item master record. Describe the attributes of the technical information and the stockkeeping information of the item master record. Identify attributes of the item master record for information on costs and prices.
17.2.3a Bill of Material, Bill-of-Material Position, and Where-Used List
Intended learning outcomes: Present the concepts of the bill of material, of the bill-of-material position, and the where-used list.
17.2.3b Single-Level Bill of Material, Multilevel Bill of Material, and Summarized Bill of Material
Intended learning outcomes: Differentiate between the single-level bill of material, the multilevel bill of material, and the summarized bill of material.
17.2.3c Single-Level Where-Used List, Multilevel Where-Used List, and Summarized Where-Used List
Intended learning outcomes: Differentiate between the single-level where-used list, the multilevel where-used list, and the summarized where-used list.
17.2.3d The Bill-of-Material Position and the Where-Used-List Position as a Logistical Object
Describe the bill-of-material position and the where-used-list position as logistical objects. Identify its most important attributes.
17.2.4 Work Center Master Data
Intended learning outcomes: Present the work-center business object. Describe the attributes of the work-center master record relating to capacity, concerning costs, and for calculating the lead time.
17.2.5 The Work Center Hierarchy
Intended learning outcomes: Present the concepts of workstation and cost center. Explain the work center hierarchy.
17.2.6 Operation and Routing Sheet
Intended learning outcomes: Present the operation business object in association with the routing sheet. Describe its attributes. Identify the work center where-used list.
17.2.7 Production Equipment, Bill of Production Equipment, and Bill of Tools
Intended learning outcomes: Present the concepts of bill of production equipment and bill-of-production-equipment position as well as production equipment where-used list. Produce an overview on collective tool, bill of tools, bill-of-tools position, and tool where-used list.
