Merge production files

The purpose of the Merge production files process is to combine matching operations in the calculations of several production files. This could reduce the setup time, for instance. The lead times of the operations will become shorter, because a machine needs to be set up only once. The operations will be performed more efficiently, resulting in lower part costs.

When production files are merged, also the part calculations are cumulated. This is done for clarity and does not result in any cost savings. In order to allow you to continue scheduling the merged operations, they are cumulated and included in a new or existing target production file.

Note: Merging production files could reduce the amount of financial information available, for example about the relationship between costs and revenues. Production files from different sales orders can be merged into one production file if the conditions set out below are true. The original production files may, however, differ in sales type (order type). During a merge operation, the merged production file will be assigned the sales type of the first production file. All WIP and costs postings will now follow the sales type of the merged production file.

Merging production files

When merging production files, there will be a source production file and a target production file. Merging involves copying calculation lines from the source production file to the target production file, where the calculation lines of the source production file are processed in a particular way in the (already existing) calculation of the target production file.

The source production file will continue to exist after the merge operation, but it will be marked as 'Merged', which will prevent it from being changed and avoid double counts when performing the planning, calculating part requirements, etcetera. In addition, these merged production files are unlinked from any parent sales lines, any part calculation lines in production files, and any underlying production files. These links are set for the target production file, as a result of which the actual costs of the underlying production files can be routed via the target production file and will not end with the unlinked source production files.

Restrictions when merging production files

• The source and target production files may not be confirmed as complete.
• The source and target production files must have the same production status type. This means the production status type must be 'Offer' or 'Order'.
• No actual costs may be posted against the source production file.
• Target production files cannot become source production files themselves.
• The parts included in the production files to be merged must have the same length, width, and height, both in the header and in the underlying calculation.
• The production files to be merged may not contain any underlying production files.

Merge result

Once merged, the original, individual production files will be assigned a 'History' status. This also applies to the routing. If desired, you can also manually enter the new status of the original production files and the target production file in the relevant fields.

When merging two production files, where one has a longer setup/adjustment time than the other, Isah will use the longer setup/adjustment time. For operations, the software checks the Capacity groupsettings.

Note: Subsequent operations are lost in the target production file. You cannot diverge or converge either. Equipment items are not merged, as they are always unique. External operations are not merged either.