# 06 — Integrations & Consolidated Data Model > How the Manufacturing module connects to the existing ERP, plus the full relational model in one place. Inherits all rules from `00`. --- ## 6.1 Integration Map The Manufacturing module is NOT an island. It integrates with modules that already exist in the host ERP (do not rebuild them). ``` ┌─────────────┐ Sales Order →│ │→ Procurement (Planned POs from MRP) │ MANUFACTURING│ Inventory ↔│ MODULE │↔ General Ledger (all postings) (RM, WIP, FG) │ │ └─────────────┘ ↕ HR (labor rates / piece-rate payroll) ``` ### Integration points (by direction) | External module | Direction | What flows | |---|---|---| | **Sales** | → Mfg | Customer orders trigger MTO/Toll production; promised dates returned | | **Procurement** | ← Mfg | MRP emits Planned Purchase Orders; receipts update availability | | **Inventory** | ↔ Mfg | Material reservations, RM→WIP→FG movements, batch/lot, consignment (customer-owned) stock | | **General Ledger** | ← Mfg | Every issue/confirmation/GR posts journal entries (WIP, applied labor/machine/OH, variances) | | **HR** | → Mfg | Labor rates; piece-rate quantities feed payroll | ### Key integration rules - **Consignment (toll):** customer-owned material lives in a separate inventory bucket (`ownership=Customer`), never valued as own asset, never triggers purchase. - **GL postings are real-time**, woven into execution events — not a nightly batch. - **Reservations** in Inventory are created at order Release, consumed at Material Issue. --- ## 6.2 Consolidated Relational Data Model All entities across the module, with keys and relationships. (Types are indicative; implement per host ERP conventions.) ### MASTER DATA ``` Item (host ERP, referenced) item_id PK, name, uom, procurement_type, material_ownership, costing_method, lead_time_days, safety_stock, ... BOM_Header bom_id PK, parent_item_id FK→Item, bom_type, version, base_quantity, uom, status, effective_from, effective_to, created_by, approved_by BOM_Line bom_id FK→BOM_Header, line_no, component_id FK→Item, quantity, uom, scrap_percentage, issue_type, issue_level, operation_seq, substitute_items (BOM_Header 1—* BOM_Line) Routing_Header routing_id PK, item_id FK→Item, routing_type, version, lot_size_from, lot_size_to, status, effective_from, effective_to, total_lead_time Routing_Operation routing_id FK→Routing_Header, operation_no, description, work_center_id FK→Work_Center, tool_id FK→Tool, setup_time, run_time_per_unit, cavity_count, cycle_time, queue_time, move_time, inspection_required, critical_operation, required_skill_code (Routing_Header 1—* Routing_Operation) Work_Center wc_id PK, description, category, plant_location, cost_center_id FK→Cost_Center, capacity_unit, daily_capacity, capacity_multiplier, efficiency_percent, utilization_percent, calendar_id, setup_cost_rate, labor_cost_rate, machine_cost_rate, overhead_rate, labor_calc, bottleneck_flag Tool (Resource, resource_type=Tool) tool_id PK, description, product_id FK→Item, cavity_count, setup_time, status, life_cycles, cycles_used, purchase_cost ``` ### PLANNING ``` MPS_Header id PK, plan_name, plant_id, time_bucket, start_date, end_date, frozen_fence, slushy_fence, status MPS_Line mps_id FK→MPS_Header, product_id FK→Item, period_date, forecast_qty, confirmed_orders_qty, planned_production, projected_balance, safety_stock_target, available_to_promise Item_MRP_Settings item_id FK→Item, mrp_type, procurement_type, material_ownership, lot_sizing_rule, lot_size, min_lot, max_lot, safety_stock, lead_time_days, reorder_point MRP_Planned_Order (transient — regenerated each run) item_id FK→Item, order_type, quantity, required_date, release_date, source_demand_id, mrp_run_id CRP_Load (output) resource_id, resource_type, period, required_load, available_capacity, utilization_pct, status ``` ### EXECUTION ``` Production_Order_Header order_no PK, order_type, product_id FK→Item, quantity, production_type, material_ownership, start_date, finish_date, status, bom_snapshot_id, routing_snapshot_id, tool_id FK→Tool, wip_account Order_Component order_no FK→PO_Header, component_id FK→Item, required_quantity, issued_quantity, reserved_quantity, operation_seq Order_Operation order_no FK→PO_Header, operation_no, work_center_id FK→Work_Center, tool_id FK→Tool, planned_setup_time, planned_run_time, actual_setup_time, actual_run_time, status, actual_start_time, actual_end_time, confirmed_by, confirmed_quantity, scrap_quantity (status ∈ Waiting/Ready/InProgress/Completed — used by SFC) Material_Issue_Header issue_no PK, issue_date, issue_type, issue_level, order_no FK→PO_Header, operation_no, issuer_id, warehouse_from, status Material_Issue_Line issue_no FK→MI_Header, material_code FK→Item, quantity, batch_no, cost_price, total_cost, bin_location, ownership Confirmation_Header confirmation_no PK, order_no FK→PO_Header, operation_no, confirmation_type, operator_id, work_center_id, shift, timestamp Confirmation_Yield confirmation_no FK→Conf_Header, grade_code, quantity, unit_sale_price Confirmation_Detail confirmation_no FK→Conf_Header, scrap_quantity, rework_quantity, setup_time_actual, run_time_actual, labor_hours, machine_hours, reason_code Goods_Receipt_Header gr_no PK, gr_date, order_no FK→PO_Header, receipt_type, warehouse_to, receiver_id, status Goods_Receipt_Line gr_no FK→GR_Header, item_id FK→Item, received_quantity, grade_code, batch_no, bin_location, cost_per_unit, quality_status ``` ### COSTING ``` Standard_Cost item_id FK→Item, std_material_cost, std_labor_cost, std_overhead_cost, std_total_cost, last_updated, update_frequency Cost_Center cc_id PK, type, parent_cc FK→Cost_Center, manager_id, budget_amount, actual_amount, status Variance_Record order_no FK→PO_Header, variance_type, amount, percentage, classification, owner, investigation_flag ``` ### CROSS-CUTTING ``` Pegging (Many-to-Many demand↔supply) production_order_id FK→PO_Header, sales_order_id FK→SalesOrder, allocated_quantity Delivery_Schedule (order splitting) schedule_id PK, parent_order_id FK→SalesOrder, quantity, scheduled_date, status, linked_production_order FK→PO_Header ``` --- ## 6.3 Relationship Summary (key cardinalities) ``` Item 1—* BOM_Header 1—* BOM_Line *—1 Item (component) [recursive multi-level] Item 1—* Routing_Header 1—* Routing_Operation *—1 Work_Center Routing_Operation *—1 Tool Work_Center *—1 Cost_Center Sales_Order *—* Production_Order (via Pegging) Sales_Order 1—* Delivery_Schedule Production_Order 1—* Order_Component / Order_Operation Production_Order 1—* Material_Issue 1—* Material_Issue_Line Production_Order 1—* Confirmation 1—* Confirmation_Yield (grades) Production_Order 1—* Goods_Receipt 1—* Goods_Receipt_Line (per grade) Production_Order 1—* Variance_Record ``` --- ## 6.4 Build Order (recommended for the AI builder) ``` 1. Master Data entities + CRUD (BOM recursive, Routing, WC, Tool) 2. Item_MRP_Settings + Standard_Cost 3. MPS (forecast consumption, time fences, CTP) 4. MRP (recursive explosion, lot sizing, toll branch) 5. CRP (resource intersection, overload detection) 6. Production Order (snapshot, state machine, order network) 7. Material Issue (3 types, 3 levels, consignment) 8. Confirmation (grade distribution, piece-rate, postings) 9. Goods Receipt (multi-grade, variance gate, toll branch) 10. Costing (methods, elements, cost centers, 7 variances) 11. SFC (operation-status real-time, terminal UI, auto-advance, dashboard) 12. Integrations (Sales, Procurement, Inventory, GL, HR) ``` Each step depends on the prior. Honour the genericity mandate (file 00 §0.2) throughout. --- ## 6.5 Future Phases (identified, not specified) | Component | Interface to current build | |---|---| | APS (detailed scheduling) | consumes Planned Orders + Resource calendars → time-phased schedule for SFC | | Quality Management | hooks Confirmation grades/reason_codes; inspection gates on operations | | Tool/Mold Management | extends Tool entity: lifecycle, maintenance, cycle tracking, replacement alerts | | Maintenance (PM) | reduces Work_Center capacity during downtime windows | | OEE / Dashboards | consumes Order_Operation actual times + scrap | | PLM / ECO | governs BOM/Routing change orders (formalizes the Snapshot concept) |