Receiving Substitute Parts on Shop Orders—Extended 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 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. If you haven't done so already, 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 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 Warehouse 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 21-340 Radiator 10
Your Site 21-341 Thermostat 10
Your Site 21-342 Water Pump 10
Your Site 21-343 Radiator Hose Set 10
Your Site 21-344 Cooling Line Assy 10

General exercise for Receiving Inventory Part

Shop Orders

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

Windows:
Shop Order

Note: This exercise creates the shop order used in the main exercise below. The shop order will need to be processed to the specific state for the exercise.

  1. Create a shop order for the part and quantity shown in the table below. 
  2. Process the shop order as described in the Shop Order Changes column. 
  3. Record the shop order number in the Shop Order Number column so you can quickly find the shop order for the main exercise.
Site Part Number Part Description Lot Size Shop Order Changes Shop Order Number
Your Site 21-240 Cooling System 10 Issue the component material and report the operations.

General exercise for Creating Shop Orders Manually

Main Exercise

Purpose: The purpose of this exercise is to receive a substitute part on a shop order receipt.

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

Receiving a Substitute Part on a Shop Order

There is a shop order for 10 cooling systems. Instead of the cooling system identified on the shop order, you want to receive another cooling system (part 21-241, Cooling System, Off-road) as a substitute part because of a change in production causing an unforeseen need for the substitute part. Additionally, you will want to verify that the quantity in inventory for the substitute part increases by the receipt.

  1. Open the Inventory Part Currently On Hand window. Query for the parts shown in the table below and record the total quantity available.
Site Part Number Description Total Qty Available
Your Site 21-240 Cooling System
Your Site 21-241 Cooling System, Off-road
  1. Open the Shop Order window and query for the shop order created 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 all operations completely reported and all material issued.
  2. Right-click anywhere in the Shop Order window header, point to Material Actions, and then click Receive to open the Receive Shop Order window.
  3. In the list in the Received Part area, click Substitute Part. Click in the part number field in the Received Part area, and enter 21-241 to receive the off-road cooling system.
  4. If no location records are displayed in the table on the Inventory Receipt tab, create a new record. Enter 10 in the Quantity Received field and 2C in the Location No field. If a record displays in the table, enter 10 in the Quantity Received field for that record. Save the information.
  5. Close the Receive Shop Order window.
  6. Refresh the Shop Order window, and verify that the Qty Completed field has the value of 10 and that the Products field shows that the order is completely received.
  7. To ensure that the substitute part was received into inventory, query for the 21-241 part  in the Inventory Part Currently On Hand window, and verify that the quantity has increased by 10. You can also view the records for the shop order in the Inventory Transactions History window.

Note:  When you receive a substitute part on a shop order, you do not have to receive the entire order quantity. You can receive partial quantities of the produced part's lot size, allowing you to receive both the standard part and the substitute part on the same shop order.