Setting Up Complex Assembly MRO Basic Data—Key Exercises

Note: Throughout this document, please replace any occurrences of XX with your initials, group ID, user ID or other unique prefix, in order to separate your training data from that of other students.

Main Exercises

Purpose: The purpose of this exercise is to set up Complex Assembly MRO basic data.

Define Maintenance Levels

Purpose: The purpose of this exercise is to create all possible maintenance levels for any part that you wish to maintain. A maintenance level is used to determine which parts of a structure will be exposed if you perform the routing steps of the same maintenance level.

Note: The maintenance levels below should appear in your environment. If not you will need to create them.  You may also create your own by adding your initials as a prefix to the maintenance level.

Windows:
Repair Setup Basic Data/Maintenance Level

1. Open the Repair Setup Basic Data window and click the Maintenance Level tab.
2. Create a new record.
3. Enter a new maintenance level as listed below.
4. Save the record.
5. Repeat Steps 2-4 for all records in the table below.

Define Maintenance Level Part

Purpose: The purpose of this exercise is to create all possible maintenance levels for each part that you wish to maintain.

Windows:
Repair Setup Basic Data/Maintenance Level

1. Open the Repair Setup Basic Data window and click the Maintenance Level Part tab.
2. Query for the maintenance level ML1.
3. Create a new record in the table area.
4. In the field Part No field, enter PP/XX_ENG.
5. Use the List of Values to enter a site in the Site field.
6. In the Disassembly Level list, click Full Disassembly and save.
7. Repeat the process for all the records in the table below.

Hint: You can copy from one maintenance level to another using the Copy Object feature once you create all the records needed for one maintenance level. Change the description in the Maintenance Description for Part field. Before doing this, make sure you change your default site to your MRO site.

Define Maintenance Level Structures

 Purpose: The purpose of this exercise is to define maintenance level structures. Maintenance level structures describe what components of a parent part are affected when a disassembly/assembly occurs.

Windows:
Maintenance Level Structure

1. Open the Maintenance Level Structure window and query for records in your site where Position Part No is PP/%.
2. Select the record with Position Part No. PP/XX_ENG, Structure Type Disassembly and Structure Revision 1.
3. Click in the Maintenance Level table and create a new record with ML1 as the Maintenance Level.
4. Save the record.
5. Select the component parts to include in the lower window, according to the table below, by selecting the check boxes for the parts to include. Then save the record.
6. Select the row in the middle table, right-click and then click Activate. This action will change the record status to Active.
7. Repeat the steps 2 to 6 for all records in the table below.

Hint: You may also use one of the three options available in the Copy Maintenance Levels right mouse button option to copy maintenance levels from assembly maintenance level structure to disassembly maintenance level structure and vice-versa. This is also used to copy maintenance levels from one revision to another revision.
Copy maintenance level structure action copies all the defined maintenance levels of source maintenance level structure along with included component data for each maintenance level to the destination.

Define Maintenance Level Routings

Purpose: The purpose of this exercise is to define maintenance level routings.

Windows:
Maintenance Level Routing

1. Open the Maintenance Level Routing window and query for records in your site where Position Part No is PP/%.
2. Select the record with Position Part No. PP/XX_ENG, Routing Type Disassembly and Structure Revision 1.
3. Click the Maintenance Level table and create a new record with ML1 as the Maintenance Level.
4. Save the record.
5. Select few operation numbers to include in the lower window by selecting the check boxes for the operations to include. Then save the record.
6. Select the row in the middle table, and right-click and then click Activate. This action will change the record status to Active.

7. Repeat steps 2 to 6 for all records in the table below.

Hint: You may also use one of the three options available in the Copy Maintenance Levels right mouse button option to copy maintenance levels from assembly maintenance level routing to disassembly maintenance level routing and vise-versa. This is also used to copy maintenance levels from one revision to another revision.
Copy maintenance level routing action will copies all the defined maintenance levels of source maintenance level routing to the destination.

Define Repair Codes

Purpose: The purpose of this exercise is to learn how to define the repair codes that will be available for the disposition process.

Note: The repair codes below should appear in your environment. If not you will need to create them. You may also create your own repair codes by adding your initials in front of the repair code.

Windows:
Repair Setup Basic Data/Repair Code

1. Open the Repair Setup Basic Data window and click the Repair Code tab.
2. Create a new record.
3. Enter a new repair code as listed below.
4. Save the record.
5. Repeat steps 2-4 for all records in the table below.

Define Repair Code Part

Purpose: The purpose of this exercise is to define the repair codes available for each part. Repair codes identify what parts and operations to use for repairing or, in other words, dealing with a specific part with a specific fault or problem.

Note: This is done for real parts and not for position parts. This connects each part to each type of repair that can be performed on that part.

Windows:
Repair Setup Basic Data/Repair Code Part

1. Open the Repair Setup Basic Data window and click the Repair Code Part tab.
2. Query for the record where the repair code is 1.
3. Create a new record in the table area.
4. In the Part No field, enter XX_A.
5. In the Site field, enter your site and save the record.
6. Create repair code part records for all records in the table below.

Hint: You can copy from one repair code to another using the Copy Object feature once you create all the records needed for one repair code. Change the description in the Repair Code Description field. Before doing this, make sure you change your default site to your MRO site.

Define Repair Code Structures

Purpose: The purpose of this exercise is to define subsets of material, in addition to the repair part itself, that is required in order to complete the repair, using a given repair code.

Windows:
Repair Code Structure

1. Open the Repair Code Structure window.
2. Query for records of part number XX_A in your site.
3. Create a new record in the middle table and in the Repair Code field, enter 1 and save.
4.  For each record in the middle table, view the components in the lower table (these are fetched from the repair structures you defined in a previous exercise). Indicate which components should be included for a specific repair job by selecting the Included check box.
5. Repeat steps 3 to 4 for repair codes 2 and 3.
6. Select all the lines in the middle table, right-click and then click Activate to activate repair codes.
7. Repeat steps 2 to 6 for all records in the table below.

Define Repair Code Routings

Purpose: The purpose of this exercise is to define subsets of operations that are required in order to complete the repair, using a given repair code.

Windows:
Repair Code Routing

1. Open the Repair Code Routing window.
2. Query for records of part number XX_A in your site.
3. Create a new record in the middle table and in the Repair Code field, enter 1 and save.
4.  For each record in the middle table, view the operations in the lower table (these are fetched from the repair routings you defined in a previous exercise). Indicate which operations should be included for a specific repair job by selecting the Included check box.
5. Repeat steps 3 to 4 for repair codes 2 and 3.
6. Select all the lines in the middle table, right-click and then click Activate to activate repair codes.
7. Right-click and then click Calculate Manufacturing Lead Time in the header to calculate the lead time.
8. Repeat steps 2 to 7 for all records in the table below.

Define Discrepancy Codes

Purpose: The purpose of this exercise is to learn how to define all the available discrepancy codes available for the disposition process. Discrepancy codes are used to determine what type of discrepancies will be allowed for each part of an assembly. This way customers can track what problems have been found in their parts.

Note:The discrepancy codes below should appear in your environment. If not you will need to create them.  You may also create your own codes by adding your initials in front of the discrepancy code.

Windows:
Repair Setup Basic Data/Discrepancy Code

1. Open the Repair Setup Basic Data window and click the Discrepancy Code tab.
2. Create a new record.
3. Enter a new discrepancy code as listed below. If these are already in the table then add one with your initials.
4. Save the record.
5. Repeat steps 1-4 for all records in the table below.

Define Discrepancy Code Parts

Purpose: The purpose of this exercise is to define the discrepancy codes available for each part.

Windows:
Repair Setup Basic Data/Discrepancy Code Part

1. Open the Repair Setup Basic Data window and click the Discrepancy Code Part tab.
2. Query for records with Discrepancy Code as 1.
3. Create a new record in the table below.
4. In the Part No field, enter  XX_A.
5. Select Internal Repair Only from the MRO Service Source list.
6. Create a new record for each part number related to discrepancy code 1 in the following table.
7. Save.
8. Repeat steps 2 to 7 for discrepancy codes 2 and 3 in the following table.

Hint: You can copy from one discrepancy code to another using the Copy Object feature once you create all the records needed for one discrepancy code. Before doing this, make sure you change your default site to your MRO site.

Connecting Discrepancy Codes and Repair Codes

Purpose: The purpose of this exercise is to learn how to define the repair codes applicable for each part, site and discrepancy code combination. This is so that when a discrepancy is reported the repairs required will be called for automatically.

Windows:
Discrepancy Repair Code

1. Open the Discrepancy Repair Code window and query for records where Discrepancy Code is 1.
2. Select the row with Part No XX_A from the first table.
3. Create a new record in the second table and use the List of Values to enter a Repair Code.
4. Create more records in second table, if you wish to include more repair codes for Discrepancy Code 1.
5. Save.
6. Create records for all the Discrepancy Code and Repair code combinations given in the table below.

Connecting Modification Codes and Repair Codes

Purpose: The purpose of this exercise is to learn how to define the repair codes applicable for each part, site and modification code combination. This is so that when a modification is included, the repairs required will be called for automatically.

Windows:
Modification Repair Code

1. Open the Modification Repair Code window and query for records where Modification Code is XX%.
2. In the Mod Code list, click XX_100.
3. In the Affected Part No list, click XX_A.
4. In the MRO Service Source list, click Internal Repair Only and save the record.
5. Create a new record in the second table and use the List of Values to enter a Repair Code.
6. Select Terminating Action from Compliance list.
7. Create more records in second table if you wish to include more repair codes for Modification Code XX_100.
8. Save.
9. Repeat steps 2 to 8 for all records in the following table.

Define Disposition Codes

Purpose: The purpose of this exercise is to show you how to define available disposition codes that will be used during the disposition process. An employee will use these codes to determine what should happen to a part after it has been disassembled from its parent part.
Disposition codes are used to determine the fate of a disposed part. Depending on if discrepancies are found or if modifications are called out for, the part can be scrapped, returned to inventory or sent out for repair. If no discrepancies or modifications are found, it may simply be inspected and returned to inventory awaiting assembly. LLPs require special disposition codes since these replacement tasks do not generate repair orders.

Note: Since disposition codes are site independent, some or all of the disposition codes described in the lesson may already appear in your environment and you can use those. Add the prefix XX_ to them, in case you create your own.

Windows:
Repair Setup Basic Data/Disposition Code

1. Open the Repair Setup Basic Data window and click the Disposition Code tab.
2. Enter a new disposition code as listed below.
3. Save the record.
4. Repeat steps 1-3 for all records in the table below.
5. Select all the records you created, right click and then click Activate. This action will change the status of each disposition code from Planned to Active.

Connecting Disposition Codes and Customers

Purpose: The purpose of this exercise is to define the disposition codes available for each customer.

Windows:
Customer Disposition Code

Note: If you created your own codes in the previous exercise, use the disposition codes you defined instead of system-defined disposition codes.

1. Open the Repair Setup Basic Data window and click the Customer Disposition Code tab.
2. Create a new record.
3. Enter the disposition code and customer ID listed below and save.
4. Repeat steps 1-3 for all the records in the table below.

Connecting Fault Codes and Discrepancy Codes

Purpose: The purpose of this exercise is to connect fault codes with the disposition codes. This allows the discrepancies found during the disposition in IFS/Manufacturing to be stored in the serial's fault history in the IFS/Vehicle Information Management.

Windows:
Operations and Faults Basic Data/Fault Code Per Discrepancy

1. Open the Operations and Faults Basic Data window, and click the Fault Code Per Discrepancy tab.

2. Create a new record.
3. Enter the fault code and the disposition code you want to connect.
4. Click Save.