Work Centers

A Work Center typically corresponds to a specific machine within a given Shop Area. Work Centers must be assigned to a Shop Area and Shop Areas may contain several Work Centers.

Work Centers

The hourly cost of operating a machine, the number of hours per day the machine is in operation, and the number of Workers needed to operate the machine can all be defined at the Work Center level. In regards to MRO, maintenance expenses and equipment depreciation can also be factored into the cost, however this cost does not include labor.

Work Centers contain fields to setup scheduled maintenance parameters and define any associated equipment depreciation. The Work Center record can also store the non-stock parts used to schedule MRO jobs for repair and maintenance activities. In addition, several Work Centers may be assigned to a parent Work Center to further define maintenance requirements. An example might be a drilling machine, defined as a parent Work Center, with the machine's clutch mechanism and coolant system defined as child Work Centers.

System Navigation

  • Production > Maintenance > Work Centers

Work Centers form

The Work Centers form lists all Work Centers based on the selection chosen in the "Display" field on the toolbar.

Field/Button

Description

Activate All

Activates all Work Centers marked as Inactive in the list. Only available when selecting a display of All or Inactive.

Deactivate All

Deactivates all Work Centers marked as Active in the list. Only available when selecting a display of All or Active.

Post Deprecation G/L

If clicked, allows users to Post Depreciation for all the visible Work Centers in a single click. Details on how the system handles the posting of depreciation to the General Ledger is available in the Edit Work Center form section below.

  • Note: Beginning in version 16.00.125 clicking this button will display the "Depreciation Date" form allowing users to pick a specific date to post depreciation. This supports the ability to backdate postings.

Edit Work Center form

Opened via the "New" or "Modify" buttons on the Work Centers form.

Field/Button

Description

View Tree

Displays a list, containing the names and descriptions, of the Parent and Children Work Centers of the current Work Center.

Post Deprecation G/L

The system will take the "Current Cost" and subtract it from the "Last Posted Cost" (or the "Acquisition Cost", if depreciation has never been posted for this Work Center) and post the difference to the General Ledger, as a credit to the "Account" on the Fixed Asset tab and a debit to the "Depreciation Expense" account in Accounting > Options. All costs mentioned are defined on the Fixed Assets tab of the Work Center. This feature requires that both:

  1. On the Fixed Assets tab of the Work Center, the "Depreciation" field is not set to "None" and there is a selection in the "Account" field.
  2. On the Costing tab in Accounting > Options, there is a selection in the "Depreciation Expense" field.

This feature also applies any Facility and/or Work Center GL Overrides. The design scenario is that when the end user purchases the machinery, they will put in a non-inventory Purchase Order purchasing to the Fixed Asset "Account" (which debits it for the cost of the Work Center). They will then fill in the "Acquisition Cost" and "Acquired" date on the Work Center, as well as the account that they debited. Over time, they will slowly credit this account until the machinery is no longer worth anything to them. This will ensure that the Fixed Asset costs in the GL are always accurate in terms of the value of current inventory.

  • Prior to version 16.00.125 clicking this button would post on today's date. Beginning in version 16.00.125 clicking this button will display the "Depreciation Date" form allowing users to pick a specific date to post depreciation. This supports the ability to backdate postings.

Name

The name of the Work Center.

Description

A description of the Work Center.

Depreciation Date form

Displays when clicking the "Post Depreciation G/L button, either from the Work Centers or Edit Work Center form. Supports the ability to backdate depreciation postings. Introduced in version 16.00.125.

Field/Button

Description

Month

Select the appropriate month. Defaults to last month.

Post On

Option to select "End of Month", "First Day of Month", or "Specific Day"

Day

Select the specific date that depreciation postings for the selected Work Centers will be posted.

  • Only available when the "Post On" field is set to "Specific Day".

General Tab

Field/Flag

Description

Parent Work Center

Indicates the Work Center to which this Work Center is assigned. Several Work Centers may be assigned to a Parent Work Center to further define maintenance requirements. An example is a drilling machine, defined as a Parent Work Center, with the machine's clutch mechanism and coolant system defined as Child Work Centers.

Shop Area

Indicates the Shop Area that contains this Work Center.

Work Center Type

Defines the Work Center Type for this Work Center. Work Center Types allow maintenance schedulers to view work required across Work Centers belonging to the same Work Center Type.

Manufacturer

Stores the Manufacturer's name for the part or equipment.

Model Number

Stores the Model Number for the part or equipment.

Serial Number

Stores the Serial Number for the part or equipment.

Hourly Cost

The cost it takes per hour to run and operate the machine or equipment and perform maintenance, including depreciation, overhead costs, general machine shop costs, and specific machine costs but excluding labor. In general, the following hourly costs should be considered: 

  • Equipment operation - A common formula is [(Machine purchase cost + Expected lifetime maintenance cost) / Expected hours of operating life].
  • Overhead - Handled by the "Burden Factor" field below. Any costs not directly involved in machining a part, including administrative staff salary, equipment, furniture, building lease, maintenance, and office supplies. The cost per hour is (Sum of annual costs of overhead items / Total labor or machine hours for the year).

Once the above costs are calculated, use the guidelines below to arrive at either a general shop hourly rate or an hourly rate based on a specific piece of equipment.

  • General machine shop operation - A common formula is [(Average machine cost per hour + Labor and overhead cost per hour) x Markup].
  • Machine-specific operation - A common formula is [(Specific machine(s) cost per hour + Labor + Overhead cost per hour) x Markup].

The above summary is somewhat simplified and is usually a work in progress, as factors may change. Please reference the "Current Burden" field description on the "Costs" tab of the Item Master record for information on how Deacom calculates current burden.

Burden Factor

Used in the "Burden Calculation" field available to a Part's Item Master. With a default of "1", the goal of this Factor is to allow for the same Operation used on different Work Centers to have different results based on the "Burden Calculation". If rolling up Burden without the calculation defined, the Burden cost will be the Operation Burden multiplied by pieces per hour. If not rolling up Burden with the calculation defined, the calculation will use only the available Item Master fields.

Notes

Optional field for storing pertinent information, which is available to print on Job batch tickets.

Default

If checked, this will be the default Work Center on forms throughout the system that contain a "Work Center" field. Users may override the default if necessary.

Active

If checked, this record is active. Only active records may be used in the system.

Fixed Assets tab

Field

Description

Acquired

Indicates the date the Work Center or equipment was purchased.

Acquisition Cost

Used to store the amount the Work Center was purchased for.

Currency

Optional. Pick list used to select a Currency for this specific Work Center.

  • When posting depreciation, the system will calculate and post using this currency. If there is no currency specified, the system will use the system default currency as before. Also, the system will assume the acquisition cost is in the currency specified in this field and the current cost, and last posted cost will display in the currency selected in this field.
  • Once the first depreciation has been posted the currency can't be changed.

Depreciation

Pick list used to select the method with which depreciation costs are posted. Options are:

  • None - A specific method is not used to reduce the carrying amount of a fixed asset.
  • Straight Line - Generally used to gradually reduce the carrying amount of a fixed asset over its useful life. Designed to reflect the consumption pattern of the underlying asset, and is used when there is no particular pattern to the manner in which the asset is to be used over time. Usually the easiest method to calculate and therefor results in fewer errors.

Account

Account to which depreciation charges will be credited. The corresponding entry is a debit to the "Depreciation Expense" account on the Costing tab in Accounting > Options. 

Months

Indicates the useful life, in months, for this Work Center.

Current Cost

Displays the current cost for this Work Center. This field will display the "Acquisition Cost" if "Depreciation" is set to "None". If set to "Straight Line", this field will display as a linear interpolation from the "Acquisition Cost" to zero, based on the "Acquired Date".

Last Posted Cost

Displays the last depreciation cost for the Work Center that was posted to the GL.

Maintenance tab

Houses maintenance tasks for the selected Work Center, including details on how the tasks recur and with what prevalence, what machines or areas cannot be used during maintenance, and the priority with which tasks should be scheduled. Maintenance tasks can only be deleted if the job containing that particular Work Center has a status of "cancelled" or "closed."

Work Center Maintenance form

Opened via the "Add" or "Modify" buttons on the Maintenance tab of the Edit Work Center form.

Field/Flag

Description

Name

The name for the Work Center repair or maintenance task.

Recurring Type

Pick list used in connection with the "Frequency" field to specify the unit of when maintenance will be performed on the Work Center. Options are:

  • Calendar Days - Used in connection with the "Schedule Type", "Day Of", and "Day", the number listed in the "Frequency" field is the number of days on a calendar that will pass until maintenance must be completed.
  • Hours Used - The number listed in the "Frequency" field is the number of hours the Work Center may be used until maintenance must be completed.
  • Manual - Maintenance is not completed on a set schedule, but as the company/operators see fit. Selecting this option removes the ability to use the "Frequency" field.
  • Metered - Used in connection with the "Meter Reading" flag and "Max Meter Reading" field on this form, the number listed in the "Frequency" field is the meter reading of when maintenance must be performed. A "Metered" task will be due immediately once the meter reading exceeds the Frequency.
  • Quantity Produced - The number listed in the "Frequency" field is the number of units that may be produced on the selected Work Center until maintenance must be completed.

Frequency

Provides the interval indicating how many days, hours, or how much usage is allowed between maintenance task completion.

Schedule Type

Only used with a "Recurring Type" of "Calendar Days". Pick list used to specify the basis of how recurring maintenance tasks, based on the number of Calendar Days specified, will be rescheduled. Options are:

  • Completion Date - Maintenance tasks will be scheduled based on the date a Maintenance Job was completed.
  • Creation Date - Maintenance tasks will be scheduled based on the date a Maintenance Job was created.

For example, assume a maintenance task is set on the Maintenance tab of a Work Center with a "Recurring Type" of "Calendar Days", a "Frequency" of "7", and the "Schedule Type" is set to "Created Date". Assume a Maintenance Job is created on Monday, Sept 7th. If an MRO report is run, the "Due" column for this Maintenance task will be set to Monday, Sept 14th. Likewise, if the "Schedule Type" was set for "Completion Date" and the same Job was completed on Wednesday, Sept 9th, then running the MRO report would indicate that the "Due" column for this maintenance task would be set to Wednesday, Sept 16th.

Initial Date

Indicates the first date that the system should consider when scheduling maintenance for this Work Center. When a value is entered and MRO is run, if a Maintenance task has never had a Job finish against it, the system will use this date as the last Job finish date instead of an empty date. When a date is entered in this field, the "Last Date" in MRO gets updated with this same date. If no Jobs have been created for a Maintenance task with a "Recurring Type" of "Calendar Days" previously, then the Initial Date will be set as the "Initial Date" + "Frequency" days.

Day Of

Only used with a "Recurring Type" of "Calendar Days" and used in conjunction with the "Day" field. Pick list used to indicate how the maintenance task due date should be snapped on a calendar when using MRO. Options are:

  • Month - The maintenance task will be snapped to the "Day" indicated for the current month. For example, if "Day" is set to "3" and "Day Of" is set to "Month", the task will snap to the 3rd of the month on the calendar. If the day of the month is less than the current date, it would snap to the following month.
  • None - The maintenance task does not snap based on calendar week or month.
  • Week - The maintenance task will be snapped to the "Day" indicated for the current week. For example, if "Day" is set to "6" and "Day Of" is set to "Week", the task will snap to Saturday on the calendar. If the day of the week is less than the current date, it would snap to the following week.

Day

Only used with a "Recurring Type" of "Calendar Days" and used in conjunction with the "Day Of" field. The value entered in this field indicates the specific day of the month or week (depending on the "Day Of" selection) that the MRO calendar will snap to when scheduling maintenance tasks. The system begins a week with Monday, so with "Day Of" set to "Week", a "Day" set to "1" represents Monday and a "Day" set to "7" represents Sunday.

Part Number

Search field used to select the non-stock item that represents the maintenance or repair activity associated with the selected maintenance task. See the Managing Maintenance Parts and BOMs page for additionla details on setting up Part Numbers for maintenance tasks.

MRO Group

Search field used to assign the maintenance task to a group. MRO Groups, managed via Production > Maintenance > MRO Groups allow maintenance tasks assigned to the same group to be placed together on the same Job when creating the Job via MRO.

Unavailability Level

Pick list used to select what impact this maintenance task will have on a machine's or location's availability. Options are:

  • Facility - Used when performing the maintenance task will stop the ability to operate in the Facility to which the Work Center belongs.
  • None - Used when performing the maintenance task permits the ability to operate as normal (no machinery or locations must be shut down or taken offline).
  • Shop Area - Used when performing the maintenance task will stop the ability to operate in the Shop Area to which the Work Center belongs.
  • Work Center - The default value, assuming that the Work Center cannot be used when performing the maintenance task (must be shut down or taken offline).

When Maintenance Jobs are scheduled for maintenance tasks that contain an "Unavailability Level" other than "None", the Master Production Calendar will black out the appropriate Work Centers, Shop Areas, and Facilities to indicate that they will be unavailable while maintenance is performed.

Priority

Used for scheduling purposes and to provide the default value when creating Maintenance Jobs via MRO. Tasks may be set with priorities starting from 1 to an unlimited number, with 1 being the highest priority and 5 being the default. If multiple tasks are set on one Work Center, the tasks are scheduled according to the value entered in their respective "Priority" fields.

Max Meter Reading

Used in connection with the "Meter Reading" flag. Indicates the point at which the meter will roll over when entering meter readings on Job lines that include a Work Center with a recurring type of "Metered". This field allows the system to calculate the difference before the meter rolled over to estimate when the next reading should occur.

Copy Document Category

Search field used to copy any documents attached to the Work Center (via the "View Docs" button on the Edit Work Center form) over to MRO Jobs created for this maintenance task. The documents must belong to the selected Document Category (selected when initially attaching the documents to the Work Center) to be copied to the Job. The documents can be used as part of the batch ticket record for the Job and may be viewed via the "View Docs"* button on the Job.

Notes

Memo field used to store additional details or instructions for IT/Dev/Support MRO tasks.

Meter Reading

Used in connection with the "Max Meter Reading" field. When finishing a Maintenance Job for a task with a "Recurring Type" of "Metered" or this "Meter Reading" flag checked, the "Finish Quantity" field on the Input Production and Close/Relieve Job forms becomes the "Meter Reading" field to enter the current meter value. In addition, The MRO report looks for the last meter reading for each Work Center compared to the meter reading when the last Metered task was performed to estimate when the next Metered task should be performed. 

Notes:

  • The Meter Reading from the time the Metered task was performed is displayed in the MRO report.
  • A reasonable due date is estimated once the Metered task has been completed and another Meter Reading is entered.
  • A Metered task has no due date if the meter has never been read.
  • Meter-reading Maintenance Jobs update the Meter ("Meter" variable from the report grid) column of the MRO report for the Metered maintenance task. The maintenance tasks based on the meter will show the Meter Reading at the time they were last performed.
  • Due dates for Metered tasks are calculated regardless of previous production. The system will also extrapolate dates for Metered task functionality to search up the tree for production in parent Work Centers. This is designed on the idea that Work Centers below top level production Work Centers on the Work Center tree, possibly several levels deep, are for MRO purposes only, and will usually not have Production Jobs assigned to them.

GL Overrides tab

Companies have the option to set GL overrides on Work Centers for the purpose of relieving materials from a Job. This option is particularly useful for Maintenance Jobs where the expenses involved with maintaining the Work Center should apply to an account different from the one specified in the "Material Expense" field of the Part's Item Master. When finishing a Job, the first Work Center in the Job Line Routing Sequences is used to apply GL Overrides to the Material Expense account when relieving materials. When relieving excess WIP, the item uses the first Routing Sequence of the first Job Line that uses that item. When finishing, a two-step close with a Routing applies the GL Overrides in both relief postings using the first Sequence for each Job Line. Additional information regarding Account Structure and the setup of account positions as well as the setup of GL Overrides is available via Accounting > Maintenance > Account Structure and Configuring GL Overrides.

Edit GL Override form

Opened via the "Add" or "Modify" button on the GL Overrides tab of the Edit Work Center form.

Field

Description

Position

Indicates the Account Position where the override will take effect. 

GL Override

Indicates the actual number of the GL sub account where the posting will take effect.

User Fields tab

Deacom allows the creation of user-defined fields that, once created, are available on various master data records such as items, Vendors, and Ship-to Companies. These fields allow companies to enter and store information outside of the fields provided in the system. The user fields on the Work Center record may be used to capture information such as Serial Number and Vendor for a piece of machinery. User fields may be added via Tools > Maintenance > User Fields. For more information, refer to Configuring User Fields and User Calculations.