Creating Repair Shop Orders—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 and needs to be done only once for the Discrete
Manufacturing courses exercises.
- Set up your site for discrete manufacturing of racing engines.
General
exercise for Overview of Discrete Manufacturing Data
Inventory Locations
Purpose: The purpose of this exercise is to set up
inventory picking locations for running functionality isolated by site.
Windows:
Inventory Locations
- If you haven't done so already, create the inventory picking locations
shown in the table
below.
Site |
Location No |
Warehouse |
Location Name |
Location Group |
Your Site |
1A |
Secondary Wareh |
Secondary |
30 |
Your Site |
2C |
Sub |
Subassembly inv |
30 |
General exercise for
Entering Inventory Locations
Repair Product Structure
Purpose: The purpose of this exercise is to set
up the repair product structure for the discrete racing
engine cooling system on your site.
Windows:
Product Structure
Product Structure/Product Structure
Note: The destination revision number will automatically
change from the source revision number to the next higher integer.
Therefore, you must change the site to your site and change the revision number
to match the source revision number. Also, the Structure Type
may default to
a value other than Repair. Verify
that the Structure Type field displays Repair.
- If you haven't done so already, create a repair product structure revision
for the part in the table below. (To make this easier, open the
Product
Structure window, query for the part and your site, select
the manufacturing revision and use the duplicate command to make a copy of
the record. Change the Structure
Type field on the new record to Repair.)
- Copy the newly-created repair structure revision from the part on site 1 to your site
by right-clicking and then clicking Copy Structure Revision.
- Set the structure alternate for the part just copied to your site to Buildable.
Site |
Part No |
Part Description |
Your Site |
21-240 |
Cooling System |
General exercise for Copying
Revisions
Repair Routing Revision
Purpose: The purpose of this exercise is to set up the
repair routing revision for the discrete racing
engine cooling system on your site.
Windows:
Routing
Note: The destination revision number will automatically
change from the source revision number to the next higher integer.
Therefore, you must change the site to your site first and then change the
revision number to match the source revision number. Otherwise an overlapping
date range may result. Also the Routing Type field may default to a
value other than Repair. Verify that the Routing Type field displays Repair.
- If you haven't done so already, create a repair routing revision for the
part shown in the table below. (To make this easier, open the
Routing
window, query for the part and your site, select
the manufacturing revision and use the duplicate command to make a copy of
the record. Change the Routing Type field on the new record to Repair.
You also may want to change the
value of the Phase In Date to match that of the manufacturing
revision.)
- Copy the newly-created repair routing revision for the part from site 1 to your site
by right-clicking and then clicking Copy Routing Revision.
- Set the routing alternate for the part just copied to your site to Buildable.
Site |
Part No |
Part Description |
1 |
21-240 |
Cooling System |
General exercise for Copying
Revisions
Required Data
Inventory Part Balance
Purpose: The purpose of this exercise is to show you the
required data that is used in the exercises below.
Windows:
Inventory Part Currently On Hand
Receive Inventory Part
- Open the
Inventory Part Currently On Hand window.
- Verify you have the correct quantity available for repair for the part and
locations shown in
the table below. If you do not have enough parts in the location, receive
the appropriate number of parts into
the inventory picking location so the available quantity matches with the
quantity specified on the table. Quantity available is the quantity on hand less any quantity that
is reserved or in transit.
Site |
Part Number |
Part Description |
Location No |
Quantity Available |
Your Site |
21-240 |
Cooling System |
1A |
2 |
Your Site |
21-240 |
Cooling System |
2C |
2 |
General exercise for
Receiving Inventory Part
Main Exercise
Purpose: The purpose of this exercise is to create a
repair shop order.
Windows:
Shop Order
Shop Order/Detail
Shop Order/Material
Shop Order/Operation
You need to repair two defective cooling systems that exist in inventory.
Therefore, you decide to create a repair shop order.
- Open the
Shop Order window and create a new record.
- If the value for the Site field is not your site, change it to your
site.
- In the Part No. field, enter 21-240 as the part to be repaired.
- In the Lot Size field, enter 2 for the quantity to be repaired.
- In the Shop Order Type list on the header, click Repair.
- Save the information.
- Record the value that the system automatically generated for the Order No. field.
(This will make it easier for you to query your shop
order.)
- Click the
Material tab and verify
that each component part shown in the table below has a record.
Notice that the components are from the repair structure and not the
structure for manufacturing. Also, the part 21-240 (Cooling System), which
has a quantity per
assembly of 1, has been added to the material list. Finally notice that the
value for the Line Item No field in each row does not match the value
in the Structure
Line No field. The row for the part to be repaired does not have a value for Structure
Line No because it was not a component part on the repair structure.
Component Part |
Description |
Qty Per Assembly |
Qty Required |
Structure Line No |
21-240 |
Cooling System |
1 |
1 |
|
21-341 |
Thermostat |
1 |
1 |
1 |
21-342 |
Water Pump |
1 |
1 |
2 |
21-343 |
Radiator Hose Set |
1 |
1 |
3 |
- Click the
Operation tab and verify
that each operation shown in the table below has a record. Notice
that the operations are from the repair routing and not the routing for
manufacturing.
Operation No |
Operation Description |
Work Center No |
Work Center Description |
Remaining Mfg Hours |
10 |
Disassemble System |
300 |
General Assembly |
0.4 |
20 |
Replace Parts |
300 |
General Assembly |
0.2 |
30 |
Assemble System |
300 |
General Assembly |
0.8 |
40 |
Test System |
810 |
Test |
0.4 |
- If value of the State field is Planned, right-click anywhere in the
Shop Order window header, and then click Release.
- When the Release Shop Order dialog box appears, click OK.
- Click the
Material tab and select the row for the 21-240 part.
Right-click on the row and then click Manual issues to issue the specific
cooling systems that need repair.
- When the
Manual Issue window appears, enter 2 in the Qty to Issue
field on the location 1A row.
- Save the information and close the
Manual Issue window. You have
issued the cooling systems that need repair. You also could have reserved the
specific cooling systems by right-clicking on the row and clicking Manual reservations
instead.
Note: Further processing of repair shop orders is
handled in the same way as other shop orders. The Discrete Manufacturing course will not use
this shop order after this exercise, so you may further process this shop order if
desired.