Discrete Manufacturing Process—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
basic data that is used in the Discrete Manufacturing exercises. This sets up
data for your site and needs to be done only once for the Discrete Manufacturing
course exercises.
- 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 an
inventory picking location for running functionality isolated by site.
Windows:
Inventory Locations
- If you haven't done so already, create the inventory picking location in the table
below.
Site |
Location No |
Warehouse |
Location Name |
Location Group |
Your Site |
2C |
Sub |
Subassembly inv |
30 |
General exercise for
Entering Inventory Locations
Required Data
System Parameters
Purpose: The purpose of this exercise is to verify that
the system default for creating shop orders is set correctly for the main
exercises below.
Windows:
Parameters for Distribution and Manufacturing
- Verify that the value for Create SO in status Planned is Yes.
General
information about System
Parameters
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
- 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 |
2 |
Your Site |
21-331 |
Starting System |
2 |
Your Site |
21-332 |
Battery System |
2 |
General exercise for
Receiving
Inventory Part
Main Exercises
Purpose: The purpose of this exercise is to follow the
state of a shop order from creation to completion.
Windows:
Shop Order
Shop Order/Detail
Shop Order/Material
Shop Order/Operation
The electrical system for the racing engine is manufactured using a
simplified shop order process that backflushes all of the material and work on the
operations. Two electrical systems will be produced. However, the
receipt of the parts will be reported one at a time so that the status on the
shop order can be observed.
The exercises below must be performed in the order
listed. If you stop between exercises, it will be necessary to query for your
order and then start where you left off.
- Open the
Shop Order window and create a new record.
- If the value for Site is not your site, change the value to your
site.
- In the Part No. field, enter 21-230 as the part to be manufactured.
- In the Lot Size field, enter 2 for the quantity to be manufactured.
- Save the information.
- Record the value that
was automatically generated for the Order No. field so that it will be easy for you
later to query for 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. Since the manufacturing lead
time for the electrical system is one day, the Finish field should
contain the next working day after the date in the Start field and the Need
Date field should contain the next working day after the date in the Finish
field.
- Verify that the shop order has been created with the Planned state.
- On the
Detail tab, verify that the value for the Qty Complete
field is zero
and the value of the Products
field is No Receive. In the State area, verify that the value of the Material
field is No Issues, and the value of the Operations field is No Report.
- Verify that the structure and routing revision and alternative fields on the
Detail tab have
the appropriate values based on the start date of the shop order. Unless the
structure or routing revision has been phased out, the value for both
revisions should be 1 and the value for both alternatives should be *.
- Click the
Material tab and verify
that there is a record with a Planned state for each component
part.
- Click the
Operation tab and verify
that there is a record to assemble the parts with an operation state of Planned.
- Right-click anywhere in the header of the
Shop Order window, and then click Release.
- When the Release Shop Order dialog box displays, click OK.
- Verify that the state in the header has changed to Released.
- Click the
Operation tab and verify that the operation state has changed to
Released.
- Click the
Material tab and verify
that the state of each record is Released. Also verify that
the values of the Qty Assigned and Qty Issued fields are zero and the value of
each Qty Remaining
field is 2.
- Right-click anywhere in the header of the
Shop Order window,
point to Material Actions, and then click Reserve.
- When the Reserve Shop Order dialog box displays, click OK
without entering anything in the Reserve to Date field.
Note: If the states are not correct in the next steps, it probably
is due to not having the necessary quantity of the components available
in inventory.
- Verify that the state in the
Shop Order window header has changed to
Reserved.
- Click the
Material tab and verify that the state of each record
has changed to Reserved. Also verify that the value of each Qty
Assigned field has changed to 2 and the value of each Qty Remaining
field has
changed to zero.
- Click the
Operation tab and verify
that the operation state is still Released.
- Click the
Detail tab and verify
that the value in the Qty Complete field is zero and that the Products
field displays No Receive.
- Right-click anywhere in the header of the
Shop Order window,
point to Material Actions, and then click Manual Receive.
- When the
Receive Shop Order window displays, select the Receive
With Backflush check box.
- Select the Auto Report Of Operations check box.
- On the
Inventory Receipt tab (in the
Receive Shop
Order window), check for a record for location 2C. If a record for location 2C does not
appear, create a
new record, entering 2C in the Location
No field. If there is already such a record, use it.
- In the Quantity Received field, enter 1.
- Save the information.
- Close the
Receive Shop Order window.
- In the
Shop Order window, query for your shop order.
- Verify that the state in the header has changed to Started.
- On the
Detail tab, verify that the Qty Complete
field now displays 1 and that the value in the Products
field has changed to Partially Received. In the State area, verify that the value of
the Material
field is Partially Issued, and the value of the Operations field is Partially Reported.
- Click the
Material tab and verify
that the state of each record has changed to Issued. Also verify that the
value of each Qty
Assigned field has changed to 1 and the value of each Qty Issued
field has changed to 1.
- Click the
Operation tab and verify
that the operation state has changed to Partially Reported.
- Right-click anywhere in the header of the
Shop Order window,
point to Material Actions, and then click Manual Receive.
- When the
Receive Shop Order window displays, select the Receive
With Backflush check box.
- Select the Auto Report Of Operations check box.
- On the
Inventory Receipt tab (in the
Receive Shop
Order window), find the record for location 2C and enter 1 in
the Quantity Received field.
- Save the information.
- Close the
Receive Shop Order window.
- In the
Shop Order window, query for your shop order.
- Verify that the state in the header has changed to Closed.
- On the
Detail tab, verify that the value in the Qty Complete
field has changed to 2 and that the Products
field now displays Completely Received. In the State area, verify that the value of
the Material
field is Completely Issued, and the value of the Operations field is
Completely Reported.
- Click the
Material tab and verify
that the state of each record
has changed to Closed. Also verify that the values of each Qty
Assigned field has changed to 0 and the values of each Qty Issued
field has changed to 2.
- Click the
Operation tab and verify
that the operation state has changed to Closed.