Creating Shop Orders Manually—Key Exercises

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.

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

General exercise for Overview of Discrete Manufacturing Data

Inventory Location

Purpose: The purpose of this exercise is to set up an inventory picking location for running functionality isolated by site.

Windows:
Inventory Locations

1. If you have not done so already, create the inventory picking location shown in the table below.

General exercise for Entering Inventory Locations

Required Data

System Parameters

Purpose: The purpose of this exercise is to ensure that the system parameters are set correctly for the main exercises below.

Windows:
Parameters for Distribution and Manufacturing

1. Open the Parameters for Distribution and Manufacturing window.
2. Verify that the value for the Create SO in status Planned field is Yes.

General information for System Parameters

Inventory Part Balance

Purpose: The purpose of this exercise is to ensure that the right quantities are available for manufacturing before you start the main exercises below. 

Windows:
Inventory Part Currently On Hand
Receive Inventory Part
Issue Inventory Part

1. Open the Inventory Part Currently On Hand window.
2. Verify that you have the correct quantity available for the part in the table below. If you do not have enough parts, receive the appropriate number of parts into the inventory picking locations so that the available quantity meets what is specified on the table. If you have more parts than specified on the table, issue the appropriate number of parts from inventory picking locations so that the available quantity falls within the range indicated on the table. 

General exercise for Receiving Inventory Part

General exercise for Issuing Inventory Part

Main Exercises

Purpose: The purpose of these exercises is to create a shop order, see the resulting load on work centers, and see the resulting shop order material when blow-through and phantom parts are in the product structure.

Windows:
Load per Work Center
Shop Order
Shop Order/Detail
Shop Order/Material
Shop Order/Operation

You need to create shop orders for two engine assemblies. You know that there are just enough piston assemblies available to build one engine assembly and you want to use the existing piston assemblies. Therefore you decide to create two shop orders, each with a lot size of one. You also want to see the load and the work centers before and after the shop orders are created.

Creating a Shop Order When Enough Phantom Components Exist

You decide to create this shop order to use the eight piston assemblies that are available in inventory.

1. Open the Load per Work Center window and query for your site. For the work centers in the table below, look at the work center load for the next two weeks. In the table below, record enough information to allow you to later recognize changes in work center load.

2. Open the Labor Load per Labor class window and query for your site. For labor class in the table below, look at the labor class load for the next two weeks. In the table below, record enough information to allow you to later recognize changes in labor class load.
3. Open the Shop Order window and create a new record.
4. If the value for the Site field is not your site, change it to your site.
5. In the Part No. field, enter 21-210 as the part to be manufactured.
6. In the Lot Size field, enter 1 for the quantity to be manufactured.
7. Save the information.
8. 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.)

Note: The Sched Direction field should have defaulted to Backwards scheduling. The Earliest Start Date and Start fields should have defaulted to the current date. The Need Date, Start, and Finish fields are calculated based on the manufacturing lead time for the engine assembly. The Need Date field should contain the next working day after the date in the Finish field.

9. Click the Material tab and verify that each component part in the table below has a record. Notice that the 21-314 part (Piston Kit), which is a blow-through part with a quantity per assembly of 8, has been replaced by its component part 21-410 (Piston Assembly) because there were at least 8 available in inventory.

10. Click the Operation tab and verify that each operation in the table below has a record.

11. Refresh the Query - Load per Work Center window and re-check each work center's load for the next two weeks. Find the changes.
12. Refresh the Labor Load per Labor class window and re-check each Labor class load for the next two weeks. Find the changes.
13. Right-click anywhere in the Shop Order window header, and then click Release.
14. When the Release Shop Order dialog box appears, click OK.
15. Verify that the state in the window header has changed to Released.
16. Refresh the Query - Load per Work Center window and re-check each work center's load for the next two weeks. Find the changes.
17. Right-click anywhere in the Shop Order window header, point to Material Actions, and then click Reserve.
18. When the Reserve Shop Order dialog box appears, click OK without entering anything in the Reserve to Date field.
19. Click the Material tab and verify that the value for the Qty Assigned field for the component part 21-410 row is 8. Depending on the available inventory, the other rows may have material assigned as well.

Note: The Discrete Manufacturing course will not use this shop order after this exercise, so you may further process this shop order if required.

Creating a Shop Order When Not Enough Phantom Components Exist

You create this shop order knowing there are not enough piston assemblies available in inventory.

1. Open the Inventory Part Currently On Hand window and query for your site and the 21-410 part. Verify that there are less than eight piston assemblies available.
2. Open the Shop Order window and create a new record.
3. If the value for the Site field is not your site, change it to your site.
4. In the Part No. field, enter 21-210 as the part to be manufactured.
5. In the Lot Size field, enter 1 for the quantity to be manufactured.
6. Save the information.
7. Click the Material tab and verify that each component part in the table below has a record. Notice that the 21-314 part (Piston Kit), which is a blow-through part with a quantity per assembly of 8, has not been replaced by its component part 21-410 (Piston Assembly) because there were fewer than 8 available in inventory. Instead the components of 21-410 have been used with the quantity per assembly of each component of 21-410 multiplied by the quantity per assembly of part 21-410. Also notice that the 21-900 expense part has a quantity per assembly of 0.

8. Click the Operation tab and verify that each operation in the table below has a record.

9. Refresh the Load per Work Center window and and again look at each work center's load for the next two weeks. Find the changes.

Note: The Discrete Manufacturing course will not use this shop order after this exercise, so you may further process this shop order if required.