Reporting Operations on Shop Orders—Key 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 is used in the Discrete Manufacturing exercises. This sets up data for your site that only needs to be done once for Discrete Manufacturing exercises.

  1. If you haven't done so already, set up your site so that it includes all the Discrete Manufacturing data for racing engines.

General exercise for Overview of Discrete Manufacturing Data

Inventory Location

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 locations shown in the table below.
Site Location No Warehouse Location Name Location Group
Your Site 1 Main Main Warehouse 30
Your Site 1A Secondary Secondary Wareh 30
Your Site 2C Sub Subassembly inv 30

General exercise for Entering Inventory Locations

Required Data

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.
Site Part Number Part Description Quantity Available for Manufacturing
Your Site 21-330 Ignition System 30
Your Site 21-331 Starting System 30
Your Site 21-332 Battery System 30

General exercise for Receiving Inventory Part

Shop Orders

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

Windows:
Shop Order

  1. Create the shop order for the part and quantity below. Release the shop order. Record your shop order number so you can easily find the appropriate shop order for each main exercise.
Site Part Number Part Description Lot Size Shop Order Number Relevant Exercise
Your Site 21-230 Electrical System 5 Report Setup Time, Report Partial Quantity and Labor, and Report Scrap.

General exercise for Creating Shop Orders Manually

Main Exercises

Purpose: The purpose of these exercises is to report on shop order operations.

Windows:
Report Work Center Operation

Reporting Setup Time

You want to report the setup time for operation 10.

  1. Open the Report Work Center Operation window. Query for your site and work center 300.Verify that at least 3 rows display in the table on the Operations tab. There also may be rows for operations on other shop orders.
  2. Identify the row for operation 10 for the shop order created for this exercise. The row will be for the 21-230 part with a default value of 5 for the Qty To Report field. Verify that Released is the value for the Operation State field.
  3. On the operation 10 row for the shop order created for this exercise, change the value in the Qty To Report field to 0, enter .1 in the Mach Setup To Report field, enter 0 in the Mach To Report field, enter .1 in the Labor Setup To Report field, and enter 0 in the Labor To Report field. Save the information. You have reported a tenth of an hour setup time (both machine and labor) for operation 10.
  4. Refresh the Report Work Center Operation window. Verify that the value of the Operation State field has changed to Setup complete. Verify that the values for each of the reporting fields have returned to their default values.

Note: You can also report the operations in the Report Shop Order Operation window and in the Dispatch List window. (windows: Report Shop Order Operation,Dispatch List). See separate training material for Dispatch List!

Reporting Partial Quantity and Labor

You want to report that two electrical systems are complete for operation 10. Then, you want to report that the remaining three electrical systems are complete for operation 10.

  1. In the Report Work Center Operation window, identify the row for operation 10 for the shop order created for this exercise. Verify that Setup complete is the value for the Operation State field. Verify that 5 is the value for the Qty To Report field, 0 is the value for the Mach Setup To Report field, 0.5 is the value of the Mach To Report field, 0 is the value for the Labor Setup To Report field, and 0.5 is the value of the Labor To Report field.
  2. Enter 2 in the Qty To Report field, 0.1 in the Mach To Report field, and 0.1 in the Labor To Report field. Save the information.
  3. Verify that the value of the Operation State field has changed to Partially reported. Verify that 3 is the value for the Qty To Report field, 0 is the value for the Mach Setup To Report field, 0.3 is the value of the Mach To Report field, 0 is the value for the Labor Setup To Report field, and 0.3 is the value of the Labor To Report field. These are the default values for the standard amount of time needed to complete the remaining 3 electrical systems.
  4. Right-click on the row, and then click Report Time. This will report the remaining quantity and time using the default values.
  5. Verify that the row no longer appears on the Operations tab of the Report Work Center Operation window.
  6. Click the Cancel Operation Reports tab. Verify that you see three rows for operation 10 on the shop order for this exercise. One row should show the report of setup time, one row should show the report of the first two electrical systems completed, and a third row should show the report of completing the last three electrical systems for operation 10.
  7. Click the Cancel Labor Operation Reports tab. Verify that you see three rows for operation 10 on the shop order for this exercise.

Reporting Scrap

You want to scrap one electrical system on operation 20.

  1. In the Report Work Center Operation window, click the Operations tab, and identify the row for operation 20 for the shop order created for this exercise.
  2. Right-click on the row, and then click Report Scrap.
  3. When the Report Scrap window displays, verify that 20 is the value of the Operation No field. Enter 1 in the Reported Scrap Qty field. Enter 10 in the Reported Scrap Reason field or click List and select a scrap reason. Click OK on the Report Scrap window to confirm that you want to scrap the electrical system on operation 20.
  4. Verify that the value of the Operation State field has changed to Partially reported. Verify that 4 is the value for the Qty To Report field, 0 is the value for the Mach Setup To Report field, 0.8 is the value of the Mach To Report field, 0 is the value for the Labor Setup To Report field, and 0.8 is the value of the Labor To Report field. These are the default values for the standard amount of time needed to complete the remaining 4 electrical systems.
  5. Close the Report Work Center Operation window.