Receiving Shop Orders Manually—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, If you haven't done so already. 

General exercise for Overview of Discrete Manufacturing Data   

Input UoM Group

Purpose: The purpose of this exercise is to connect the Input UoM Group to the inventory part in order to be able to receive the order using the Multiple Units of Measure functionality.

Windows:
Inventory Part
Input UoM Group

1. Attach Input UoM group XX_WEIGHT to the inventory part, If you haven't done so already.

General exercise for Input UoM Group         

Inventory Location

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

Windows:
Inventory Locations

1. Create the inventory picking locations shown in the table below, If you haven't done so already.

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. 

General exercise for Receiving Inventory Part  

Shop Orders

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

Windows:
Shop Order

Note: This exercise creates the shop orders used in the main exercises below. These shop orders will need to be processed to specific states for the exercises. 

1. Create shop orders for the parts and quantities below and process the shop orders as described in the Shop Order Changes column. Record your shop order numbers so you can easily find the right shop order for the main exercises. 

General exercise for Creating Shop Orders Manually

Main Exercises

Purpose: The purpose of these exercises is to receive shop orders into inventory locations manually, using backflushing of material automatic reporting of operations and using the simplified material check. It is also possible to close the shop order while receiving.

Windows:
Inventory Part Currently On Hand
Shop Order
Receive Shop Order
Inventory Transactions History

The valve train for the racing engine is a manufactured part produced from several components. For the following exercises, the following shop orders exist:

• A shop order for 5 cooling systems with the operations reported manually. You want to receive the cooling systems and backflush the component material at the same time.
• A shop order for 10 cooling systems with the component material issued. You want to receive the cooling systems and automatically report the operations at the same time.
• A shop order for 15 cooling systems with no material issued or operations reported. You want to receive the cooling systems, backflush the component material method, and automatically report the operations at the same time.
• A shop order for 100 liters of white paint with the operations reported and the partial receipt of 90 liters of white paint. You want to receive more white paint without issuing the required material.
• A shop order for 50 liters of white paint with the operations reported and components issued. You want to receive 47 liters of white paint and close the shop order at the same time.

Receiving Material with Backflush of Material

You have a shop order for 5 cooling systems with the operations reported manually. You want to receive the cooling systems and backflush the component material at the same time.

1. Open the Inventory Part Currently On Hand window. Query for the part in the table below and record the total quantity available.

2. 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 21-240 and a quantity of 5. The shop order should have a status of Started with all operations completely reported and all material reserved.
3. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive to open the Receive Shop Order window.
   

Note: It is also possible to open the Receive Shop Order window directly and query for your shop order.

4. Select the Receive With Backflush check box to indicate that the necessary component material will be issued from inventory automatically on receipt.
5. 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.
6. In the Quantity Received field, enter 5.
7. Save the information.
8. Close the Receive Shop Order window.
9. Refresh the Shop Order window and verify that the value of the Products field is Completely Received.
   

Note: If you want to see from where the component material supplied to the shop order was issued, you can view this information in the Inventory Transactions History window.

10. To ensure that the material was received into inventory, query for the 21-240 part in the Inventory Part Currently On Hand window and verify that the quantity has increased by 5. 

Receiving Material with Auto Reporting of Operations

You have a shop order for 10 cooling systems with the component material issued. You want to receive the cooling systems and automatically report the operations at the same time.

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 21-240 and a quantity of 10. The shop order should have a status of Started with no operations reported and all material issued.
2. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive to open the Receive Shop Order window.
3. Select the Auto Report Of Operations check box to indicate that the necessary work on the operations should be reported automatically on receipt.
4. On the Inventory Receipt tab (in the Receive Shop Order window), enter 10 in the Quantity Received field for the record for location 2C.
5. Save the information.
6. Close the Receive Shop Order window.
7. Refresh the Shop Order window and verify that the value of the Products field is Completely Received.
   

Receiving Material with Backflush and Auto Reporting

You have a shop order for 15 cooling systems with no material issued or operations reported. You want to receive the cooling systems, backflush the component material method, and automatically report the operations at the same time.

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 21-240 and a quantity of 15. The shop order should have a status of Reserved with no operations reported and all material reserved.
2. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive to open the Receive Shop Order window.
3. Select the Receive With Backflush check box to indicate that the necessary component material will be issued from inventory automatically on receipt.
4. Select the Auto Report Of Operations check box to indicate that the necessary work on the operations should be reported automatically on receipt.
5. On the Inventory Receipt tab (in the Receive Shop Order window), enter 15 in the Quantity Received field for the record for location 2C.
6. Save the information.
7. Close the Receive Shop Order window.
8. Refresh the Shop Order window and verify that the value of the Products field is Completely Received.

Receiving Material with Simplified Material Check

You have a shop order for 100 liters of white paint with all operations reported and the partial receipt of 90 liters of white paint. You want to receive more white paint without issuing the required material.

1. Open the Inventory Part Currently On Hand window. Query for the part in the table below and record the total quantity available.

2. 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 81-200 and a quantity of 100. The shop order should have a status of Started with all operations completely reported and a Qty Complete of 90.
3. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive to open the Receive Shop Order window.
4. Select the Simplified Material Check check box.
5. On the Receive Shop Order/Inventory Receipt tab, check for a record for the location 2C. If a record for the 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.
6. In the Quantity Received field, enter 10.
7. Save the information.
8. Close the Receive Shop Order window.
9. Refresh the Shop Order window and verify that the value of the Products field is Completely Received.
10. To ensure that the material was received into inventory without issuing material, query for the 81-200 part in the Inventory Part Currently On Hand window and verify that the quantity has increased by 10 and query for the 81-400, 81-520 and verify that the quantity remains unchanged.
     

Receiving and Close Shop Order

You have a shop order for 50 liters of white paint with all operations reported and all materials issued. You want to receive 47 liters of white paint and close the shop order at the same time.

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 81-200 and a quantity of 50. The shop order should have a status of Started with all operations completely reported and all material issued.
2. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive to open the Receive Shop Order window.
3. On the Receive Shop Order window, select the Close Shop Order check box.
4. On the Inventory Receipt tab, 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.
5. In the Quantity Received field, enter 47.
6. Save the information. The status of the shop order will be closed.

Receiving Material using an Input UoM Group

You have a shop order for 96 pcs of steel bar with no material issued or operations reported. You want to receive the steel bars in UoM 'box' where each box contains 12 pcs, backflush the component material method, and automatically report the operations at the same time.

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 30-100 and a quantity of 96. The shop order should have a status of Reserved with no operations reported and all material reserved.
2. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive to open the Receive Shop Order window.
3. Select the Receive With Backflush check box to indicate that the necessary component material will be issued from inventory automatically on receipt.
4. Select the Auto Report Of Operations check box to indicate that the necessary work on the operations should be reported automatically on receipt.
5. On the Inventory Receipt tab (in the Receive Shop Order window), right-click and select Input UoM. If no line exits for location 2C you have to press new before you can select the Input UoM.
6. Select Input UoM in the dialog box and enter the missing parameters displayed in the table. Enter 8 for value field in the table. 
7. Click Calculate to check the result. Output quantity should read 96. If the calculation is performed correctly, click OK. 
8. The calculated quantity is automatically entered in the Quantity Received field for the record for location 2C.
9. Save the information.
10. Close the Receive Shop Order window.
11. Refresh the Shop Order window and verify that the value of the Products field is Completely Received.