Creating Shop Order Requisitions for Next Level Demand—Extended Exercises

IMPORTANT
It is extremely important that you set up and work within your own site to maintain your data integrity.  If you work within any other site, you will compromise your own exercise data as well as the data of other students. Predictable exercise results require that your data be isolated in your own site. 

Basic Data Setup

Discrete Manufacturing Overview Racing Engine

Purpose: The purpose of this exercise is to create the required data that will be used in the Discrete Manufacturing exercises. This sets up data for your site that only needs to be done once for Discrete Manufacturing course exercises.

  1. Set up your site for discrete manufacturing of racing engines.

General exercise for Overview of Discrete Manufacturing Data

Required Data

Inventory Part Balance

Purpose: The purpose of this exercise is to make sure you have a zero quantity of the parts available to you.

Windows:
Inventory Part Currently On Hand
Issue Inventory Part

  1. Open the Inventory Part Currently On Hand window.
  2. Verify that you have no quantity available for manufacturing for each of the parts in the table below. If you do have any parts available, issue the quantity available for the parts.
Site Part Number Part Description Quantity Available for Manufacturing
Your Site 21-350 Fuel Tank 0
Your Site 21-351 Carburetor 0
Your Site 21-352 Fuel Pump 0

General exercise for Issue Inventory Part 

Main Exercises

Purpose: The purpose of this exercise is to familiarize you with how shop order requisitions are created for next level demand.

Windows:
Shop Order Requisitions
Shop Order
Purchase Requisition Lines
Shop Order Requisition

The fuel system for the racing engine is manufactured using a Just-In-Time system in which the shop order is used as a pull signal for the components. The manufacturing area is set up so that when a carburetor is needed, it is manufactured. Purchased material is available from the supplier in the manufacturing area as well.

Creating Shop Order Requisitions for Next Level Demand

You will see that requisitions are created for the next level components when the shop order for the fuel system is released.

  1. Open the Shop Order Requisitions window.

Note You must know which requisitions already exist so you can tell which requisitions are newly created. Therefore you will repeat the query in the next step multiple times. The results from the first query will be compared to later results of the same query.

  1. Query for your site, entering or clicking Next Level Demand in the Type list.
  2. Open the Shop Order window.
  3. Create a new record.
  4. In the header, change the value in the Site field to your site unless it already has your site as the value.
  5. Enter 21-250 in the Part No field to build a fuel system.
  6. Enter 1 in the Lot Size field and keep the default dates in the date fields.
  7. Save the information.

Note Although the shop order has been created, it has not yet been released and the requisitions have not yet been created. Therefore the results from the next query should match the results from the first query.

  1. In the Shop Order Requisitions window, repeat the previous query for your site.
  2. In the Shop Order window, right-click anywhere in the header, and then click Release.

Note Now that the shop order has been released, the results from the next query should show additional rows for the manufactured next level demand. There should be a new shop order requisition for the carburetor.

  1. In the Shop Order Requisitions window, repeat the query for your site

Creating Purchase Requisitions for Next Level Demand

You will see that requisitions are created for the next level purchased components when the shop order for the carburetor is released.

  1. Open the Purchase Requisition Lines window.

Note You must know which requisitions already exist so you can tell which requisitions are newly created. Therefore you will repeat the query in the next step multiple times. The results from the first query will be compared to later results of the same query.

  1. Query for your site and for requisitioner NLD. 
  2. Open the Shop Order Requisitions window.
  3. Query for your site, entering or clicking Next Level Demand in the Type list.
  4. Select the row with the requisition created in the previous exercise for the 21-351 part.
  5. Right-click and then click Show Shop Order Requisition to open the Shop Order Requisition window.
  6. Right-click anywhere and then click Create Shop Order(s) to convert the requisition to a shop order.
  7. Click on the Shop Order tab to see the shop order that was created.
  8. Select the row showing the shop order. Right-click and then click Show Shop Order to display the Shop Order window containing the shop order for the carburetor.

Note Although the shop order has been created, it has not yet been released and the requisitions have not yet been created. Therefore the results from the next query should match the results from the first query.

  1. In the Purchase Requisition Lines window, repeat the previous query (step 2).
  2. In the Shop Order window for the carburetor, right-click anywhere in the header, and then click Release.

Note Now that the shop order has been released, the results from the next query should show additional rows for the purchased next level demand. There should be a new purchase requisition for the throttle plate.

  1. In the Purchase Requisition Lines window, repeat the previous query.