Merging And Splitting Shop Orders—Extended 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 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

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 haven't done so already, create the inventory picking location shown in the table below.

General exercise for Entering Inventory Locations

Split Checklist Template

Purpose: The purpose of this exercise is to create your own split checklist template to be used when splitting shop orders.

Windows:
Split Checklist Basic Data/Split Checklist Template

1. If you haven't done so already, create a split checklist template on your site with at least three checklist steps.

General exercise for Split Checklist Template

Required Data

Shop Order

Purpose: The purpose of this exercise is to manually create the shop orders that will be used in the main exercises below.

1. Create shop orders for the parts and quantities shown in the table below.
2. Record the shop order numbers so that you can easily identify the correct shop order for each main exercise.

General exercise for Creating Shop Orders Manually

Inventory Part Balance

Purpose: The purpose of this exercise is to verify that you have enough parts to complete the main exercises. 

Windows:
Inventory Part Currently On Hand
Receive Inventory Part

1. Verify that you have at least the quantity of parts shown on the table below available for manufacturing. If you do not, receive the indicated quantity of the parts into inventory picking locations.

General exercise for Receiving Inventory Part

Main Exercises

Purpose: The purpose of these exercises is to process a shop order merge and several different forms of shop order splits.

Windows:
Shop Order

You are the person responsible for maintaining the shop orders. Today you need to make changes to shop orders for building an electrical system. The changes are:

• There are two shop orders for small quantities of electrical systems that you want to merge into a single shop order because that will enable you to more efficiently use work center time.
• There is a shop order for 20 electrical systems on which work has already begun. You want to split that shop order into two smaller orders because you need to schedule other work between the two smaller orders. You plan to specify the number of electrical systems for each order.
• There is a shop order for 10 electrical systems that you want to split into two smaller orders due to quality problems. You want to specify the percentage of electrical systems for the two orders.
• There is a shop order for 30 electrical systems on which you want to use a split checklist to check that all required activities have been completed before you split the shop order into multiple shop orders.

Merging Shop Orders

There are two shop orders for small quantities of electrical systems that you want to merge into a single shop order because that will enable you to more efficiently use work center time.

1. Open the Shop Order window and query for the first shop order you created for the main exercises. If you did not record the shop order number, query for your site, part number 21-230 and a quantity of 4. If the status of the shop order is Planned, release the shop order.
2. Right-click anywhere in the header, point to Merges and Splits, and then click Merge into Shop Order.
3. Verify that the Merge into Existing Shop Order option is selected. (The other option is only available for requisitions being merged into new shop orders.)
4. In the Order field under Existing Shop Order, click List and select the appropriate shop order from the List of Values. (This shop order should also be for the 21-230 part and have a lot size of 6.)
5. Click OK to merge the first shop order into the second shop order.
6. In the Shop Order window, query for both shop orders for this exercise. Verify that the first shop order is no longer available. Verify that the second shop order now has a lot size of 10 which is the sum of the two original lot sizes.

Note: Only shop orders with a status of either Planned or Released can be merged because the merged shop order is removed. Shop orders with costs, material reserved or issued, or work reported cannot be removed.

Splitting a Shop Order Using a Discrete Split

There is a shop order for 20 electrical systems on which work has already begun. You want to split that shop order into two smaller orders because you need to schedule other work between the two smaller orders. You plan to specify the number of electrical systems for each order.

1. Open the Shop Order window and query for the shop order for this exercise. If you did not record the shop order number, query for your site, part number 21-230 and a quantity of 20. If the status of the shop order is Planned, release the shop order.
2. Right-click anywhere in the header, and then click Report. When the Report Shop Order Operation window displays, enter 8 in the Qty To Report field on the operation 10 row. Save the information and close the window to complete the reporting of 8 complete for the first operation.
3. Re-query for your shop order in the Shop Order window. Verify that Started is the value in the State field.
4. Click the Material tab. Verify that 8 of the 21-330 parts have been issued to the shop order.
5. Right-click anywhere in the header, point to Merges and Splits, and then click Split Shop Order.
6. Click OK to confirm that you want to split the shop order, which has reported operations.
7. When the Split Shop Order window displays, verify that the Discrete Split option is selected. (The other option will be used in the next exercise.)
8. Create a new table row in the Split Shop Order window, and enter 12 in the Lot Size field.
9. Enter 100 in the Split Reason field or click List to select a split reason.
10. In the Order No field, you can either enter a shop order number or leave it blank to allow the system to generate the shop order number.
11. Click OK to split the shop order.
12. In the Shop Order window, verify that 8 is now the value for the Lot Size field for the original shop order.
13. Click the Material tab, and verify that the quantity issued for the 21-330 part is still 8. Verify that the quantity required for each component is now 8.
14. Click the Operation tab, and verify that the value in the Remaining Qty field is 0 and the value in the Oper State field for operation 10 is Closed. Verify that the other two operations have a remaining quantity of 8.
15. Click the Shop Order Splits tab. Verify that the fields in the Source Shop Order area have no values.
16. In the Split Shop Orders table, select the row for the new shop order that was split from the original shop order. Right-click on the row and then click Show Shop Order to open a new Shop Order window with the new shop order.
17. In the new Shop Order window, verify that 12 is the value in the Lot Size field and the status of the new shop order is Planned.
18. Click the Shop Order Splits tab. Verify that the values from the original shop order are displayed in the fields in the Source Shop Order area. (The value in the Lot Size field should be 8.)
19. Close both Shop Order windows.

Note: Any work reported on operations remains with the original shop order. If you want some of the work reported on the new shop order, you will need to make those changes manually.

Splitting a Shop Order Using a Percentage Split

There is a shop order for 10 electrical systems that you want to split into two smaller orders due to quality problems. You will specify the percentage of electrical systems for the two orders.

1. Open the Shop Order window and query for the shop order for this exercise. If you did not record the shop order number, query for your site, part number 21-230 and a quantity of 10. If the status of the shop order is Planned, release the shop order.
2. Right-click anywhere in the header, point to Merges and Splits, and then click Split Shop Order.
3. When the Split Shop Order window appears, click Percentage Split.
4. Create a new table row in the Split Shop Order window, and then enter 40 in the Split Percent field.
5. Enter 200 in the Split Reason field or click List to select a split reason.
6. You can enter a shop order number in the Order No field or leave it blank so the system generates the shop order number.
7. Click OK to split the shop order.
8. In the Shop Order window, verify that 6 is now the value for Lot Size for the original shop order.
9. Click the Shop Order Splits tab. Verify that the fields in the Source Shop Order area have no values. In the Split Shop Orders table, verify that there is a row for the new shop order that was split from the original shop order. Verify that 4 (40% of 10) is the value in the Lot Size field.
10. Close the Shop Order window.

Splitting a Shop Order Using a Split Checklist

There is a shop order for 30 electrical systems on which you want to use a split checklist to check that all required activities have been completed before you split the shop order into multiple shop orders.

1. Open the Shop Order window and query for the shop order for this exercise. If you did not record the shop order number, query for your site, part number 21-230 and a quantity of 30. If the status of the shop order is Planned, release the shop order.
2. Reserve the material on the shop order.
3. Right-click anywhere in the header, point to Merges and Splits, and then click Maintain Split Checklist.
4. When the Shop Order Split Checklist Maintenance window displays, enter the identifier for a split checklist template for your site in the Check List ID field or click List to select an appropriate split checklist template. Verify that there are at least three records in the table. Click Apply to create the split checklist for this shop order.
5. For each row in the table, read the question in the Check List Question field.
6. Select the Item Approved check box for only one row. Click Apply. Verify that your user name is now in the Item Approver field.
7. Select the Item Approved check box for another row. Verify that an Item Approved check box is clear in at least one row. Click OK to close the window.
8. To split the shop order, every item on the checklist must be approved. In the Shop Order window, verify that the Split Shop Order option is not available when you right-click anywhere in the header and point to Merges and Splits.
9. Right-click anywhere in the header, point to Merges and Splits, and then click Maintain Split Checklist.
10. When the Shop Order Split Checklist Maintenance window displays, approve the remaining items and click OK to close the window.
11. Right-click anywhere in the header of the Shop Order window, point to Merges and Splits, and click Split Shop Order.
12. When the Split Shop Order window displays, verify that the Discrete Split option is selected.
13. Create rows in the table on the Split Shop Order window, and enter the information shown on the table below to create three new shop orders when you split the original shop order.

Note: It is optional to use a split checklist to split shop orders into multiple shop orders. You can also create more than one new shop order from the split by using a percentage split.

14. Click OK to split the shop order.
15. In the Shop Order window, verify that 12 is now the value for the Lot Size field for the original shop order.
16. Click the Shop Order Splits tab. Verify that the fields under Source Shop Order have no values. Verify that there is a row in the Split Shop Orders table for each new shop order that was created by splitting the original shop order. Verify that correct values are in the Lot Size fields.
17. Close the Shop Order window.

Note: To further process split shop orders, you will handled them in the same way as you would other shop orders. The Discrete Manufacturing course will not use these shop orders after this exercise, so you may further process the shop orders if desired.