Reserving Material on Shop Orders—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 Locations

Purpose: The purpose of this exercise is to set up inventory picking locations 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

Required Data

Inventory Part Balance

Purpose: The purpose of this exercise is to ensure that you have the correct quantities of parts available for the main exercises. 

Windows:
Inventory Part Currently On Hand
Receive Inventory Part

1. Open the Inventory Part Currently On Hand window.
2. Verify that you have available parts in at least the quantity shown in the table below. If you do not have enough parts, for each part receive the appropriate number into at least two different inventory picking locations. 

General exercise for Receiving Inventory Part

Shop Orders

Purpose: The purpose of this exercise is to set up a manually created shop order with the default information, so you can modify it in the exercises below.

Note: Record the shop order numbers so it will be easy to identify the correct shop order for the exercise.

1. Create shop orders for the parts and lot sizes identified in the table below. If the status of the shop orders is Planned, release the shop orders.

General exercise for Creating Shop Orders Manually

Main Exercises

Purpose: The purpose of this exercise is to reserve inventory for component material on a shop order in different ways.

Windows:
Shop Order

You are the person responsible for maintaining the shop orders. Today you need to reserve material to shop orders for building an electrical system. The activities you want to perform are:

• You want to reserve all the material for the shop order that has a lot size of 5. You do not want to specify the inventory locations. However, you want to see which inventory locations have material reserved for the shop order.
• You decide to unreserve the battery systems from the shop order.
• You want to reserve the material linked to operation 10 on the shop order that has a lot size of 10.
• You want to manually reserve the starting systems for the shop order.

Reserving Material Automatically

You want to reserve all the material for the shop order that has a lot size of 5. You do not want to specify the inventory locations. However, you want to see which inventory locations have material reserved for the shop 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 5. If the status of the shop order is Planned, release the shop order.
2. Click the Material tab. For all three component parts, verify that the value for the Qty Required field and the Qty Remaining field is 5. For all three component parts, verify that 0 is the value for the Qty Assigned and Qty Issued fields. Also for all three component parts, verify that Released is the value for the State field.
3. Select the row for the 21-330 (Ignition System) component part. Right-click on the row, and then click Reserve. Click Yes to confirm that you want to reserve the material for the row.
4. Verify that the value for the Qty Assigned field has changed to 5, and the value for the Qty Remaining field has changed to 0. Verify that the value of the State field has changed to Reserved for this row only. You have reserved the material for this row.
5. Select the row for the 21-330 (Ignition System) component part. Right-click on the row, and then click Manual Reservations. Verify that the Reservations window shows the quantity assigned from the inventory locations. Close the Reservations window.
6. Right-click anywhere in the header, point to Material Actions, and then click Reserve. When the Reserve Shop Order dialog box appears, click OK.
7. Verify that the value for the Qty Assigned field has changed to 5 for the rest of the rows. Verify that the value of the State field has changed to Reserved for the rest of the rows. You have reserved all the material for this shop order.

Note: If you wanted to reserve multiple rows but not all the material, select the rows for the component material you want to reserve, right-click on the rows, and then click Reserve.

Unreserving Material on a Shop Order

You decide to unreserve the battery systems from the shop order.

1. Open the Shop Order window.
2. In the Material tab, select the row for the 21-332 (Battery System) component part. Right-click on the row, and then click Unreserve. Click Yes to confirm that you want to unreserve the material for the row.
3. Verify that the value for the Qty Assigned field has changed to 0 for the 21-332 component part, and the value for the Qty Remaining field has changed to 5. Verify that the value of the State field has changed to Released for this row only. You have unreserved the material for this row.

Note: If some material has been issued to the shop order and some material is reserved, clicking Unreserve will only unreserve the reserved material. It will not affect the issued material.

Reserving Material Linked to an Operation on a Shop Order

You want to reserve the material linked to operation 10 on the shop order that has a lot size of 10.

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. Click the Material tab. Verify that the value for the Operation No field is 10 for the row for the 21-330 (Ignition System) component part, and 20 for the rows for the 21-331 (Starting System) and the 21-332 (Battery System) component parts. For all three component parts, verify that the value for the Qty Required and the Qty Remaining fields is 10 . For all three component parts, verify that 0 is the value for the Qty Assigned and Qty Issued fields. Also for all three component parts. verify that Released is the value for the State field.
3. Right-click anywhere in the header, point to Material Actions, and then click Reserve Operation Material.
4. When the Reserve Material for Operation dialog box appears, enter 10 in the Operation No field. Click OK to reserve material for operation 10 and close the dialog box.
5. For the row for the 21-330 component part, verify that the value for the Qty Assigned field has changed to 10, and the value for the Qty Remaining field has changed to 0. Verify that the value of the State field has changed to Reserved for this row only. You have reserved the material for this row because it is connected to operation 10.

Note: When material is reported complete for an operation, any material connected to that operation is backflushed. Reserving the material prior to reporting the operation allows control of which material is issued from inventory.

Reserving Material Manually

You want to manually reserve the starting systems for the shop order.

1. In the Material tab of the Shop Order window, select the row for the 21-331 (Starting System) component part. Right-click on the row, and then click Manual Reservations.
2. When the Reservations window appears, verify that the values in the header fields match the values from the shop order and component material line.
3. While still in the Reservations window, create a new record in the table.
4. Click List of Values for the Location No field. The Qty Available field in the List of Values shows the quantity of the component part that is available at the inventory location. Select an appropriate location from the List of Values.
5. In the Reservations window, verify that the value in the Qty Assigned field is the smaller quantity that was available or the quantity remaining for the component part (which should be 10). In other words, the quantity assigned will be as much as is needed for the component material but not greater than the quantity that is available at the inventory location. You can change this value to a smaller quantity if desired.
6. Save the information and close the Reservations window.
7. Refresh the Shop Order window. Verify that the value in the Qty Assigned field has increased by the quantity assigned from the inventory locations and that the value in the Qty Remaining field has decreased by the quantity assigned.

Note: The Discrete Manufacturing course will not use these shop orders after this exercise, so you may further process the shop orders if desired.