DOP Follow-Up and Analysis—Extended Exercises

Basic Data Setup

Overview of Make To Order Data

Purpose: The purpose of this exercise is to simplify the process of setting up data correctly in order to complete the exercises below. It includes setting up your own site and copying specified data to that site. Before continuing with the exercises on this page, complete the lesson linked below. You need to do this exercise only once to support all Make to Order exercises in the current database.

Overview of Make To Order Data lesson

Main Exercises

Comparing DOP Structures

Purpose: The purpose of this exercise is to introduce you to the basic functionality for comparing DOP structures with each other and with the standard Bill of Material (BOM). Using an existing DOP record, you will modify the structure by selecting a structure alternative. This will allow you to compare this alternative structure with both the standard bill of material and the DOP structure created in the Creating DOP Structures lesson.

Prerequisites: You will create or use two existing DOP headers for the same part, 22-110.

Windows:
DOP Header
Comparing DOP Structures
Compare DOP Order and BOM

1. In the DOP Header window, create a new record for part 22-110, a quantity of 2, due approximately one week from today. Enter a description for the DOP to note that this DOP will use alternative *.
2. Save your changes. Note the DOP ID:_______.
3. In the header area, right-click and click Create DOP Structure, and then click Create DOP Structure. This will open the Create DOP Structure/Routings window.
4. Select structure revision number 1, structure alternative * from the List of Values.
5. Select routing revision 1, routing alternative * from the List of Values.
6. Click OK to create the DOP structure.
7. Now we will create another DOP with a different structure and routing.
8. In the DOP Header window, create a new record for part 22-110, a quantity of 2, due approximately one week from today. Enter a description for the DOP to note that this DOP will use alternative 1.
9. Save your changes. Note the DOP ID:_______.
10. In the header area, right-click and click Create DOP Structure, and then click Create DOP Structure. This will open the Create DOP Structure/Routings window.
11. Select structure revision number 1, structure alternative 1 from the List of Values.
12. Select routing revision 1, routing alternative 1 from the List of Values.
13. Click OK to create the DOP structure.
14. Click the Structure tab. You will see a DOP order for part 22-260, Governor Assembly.
15. Query for the first DOP created with alternative *.
16. In the Structure tab, you will not see a DOP order for part 22-260, Governor Assembly.
17. A better way to compare these structures is to open the Comparing DOP Structures window.
18. Click in the DOP ID field under Comparator. Query for your first DOP ID.
19. Click in the DOP ID field under Comparatee. Query for your second DOP ID.
20. Click All, Equal, and Difference to view, respectively:
    • The entire structures of both DOP IDs.
    • The parts of the structures that are the same.
    • The parts of the structures that are different.
21. Click Tree to see a tree list box with these records displayed side by side.

Note: As an alternate exercise, you can create two DOP headers for part 22-110. Set the Structure Level field to Full Level for one before creating the structures. Even when you use the same structure revision and alternative, you will see a difference when you compare structures. The Full Level setting causes the structure creation to continue to the bottom of the structure without regard to the supply type of the parts.

22. You can compare the DOP orders created above with the standard bill of materials (BOM).
23. Open the Compare DOP Order and BOM window.
24. Click the DOP ID field. Query for your second DOP ID from above, which used alternative 1.
25. Query for the default BOM. Click the Part No field. Query for part number 22-110, revision 1, alternative *, and your site.
26. Click All, Equal, and Difference to view, respectively:
    • The entire structures of the DOP and the BOM.
    • The parts of the structures that are the same.
    • The parts of the structures that are different.
27. Click Tree to see a tree list box with these records displayed side by side.

Note: As an alternate exercise, you can compare the DOP created with the Structure Level field set to Full Level to the default BOM. Note that the default BOM will show the structure that would be created for a DOP using Structure Level set to DOP Parts.

Analysis of DOP Orders

Purpose: The purpose of this exercise is to introduce you to the basic functionality for viewing a cost performance graph of a DOP structure.

Prerequisites: Structures and routings for the specified part(s) in the DOP header must already exist.

Windows:
DOP Header
DOP Order
Receive Inventory Part
Calculate DOP Cost
Monitoring Cost Performance

1. In the DOP Header window, create a new record for part 22-110, a quantity of 2, due approximately one week from today.

2. Save your changes. Note the DOP ID:_______.
3. Create the structure from the default BOM or by selecting structure and routing values.
4. Release the entire DOP.
5. You will need to receive into inventory component parts for this shop order using the Receive Inventory Part window before performing the next steps.
6. In the DOP Order window, query for the DOP ID. Select DOP Order ID 1, which is the order for part 22-110.
7. In the Supply tab, select the record in the table area, right-click and then click Go to Supply to open the pegged shop order.
8. Perform operations on the shop order by right-clicking and then clicking different options, such as Release, Material Actions, then Issue, and Report.
9. When reporting, you can choose to report more or less than the default quantity to report. You can also choose to scrap parts.
10. In the Calculate DOP Cost window, enter this DOP ID and select Standard, Estimated, and Actual, then click OK to run the costing process for this DOP.
11. Note that this is a background process and it may take a moment to complete.
12. Open the Monitoring Cost Performance window and query for your DOP ID.
13. Review the graph to see the Accumulated Cost/Value vs. Date for various projected, planned, and actual values.
14. This graph is also available in the DOP Header/Performance Monitoring tab.

Viewing a DOP using the Gantt Chart

Purpose: The purpose of this exercise is to introduce you to the basic functionality for viewing a Gantt chart of a DOP structure.

Prerequisites: Structures and routings for the specified part(s) in the DOP header must already exist.

Windows:
DOP Header
DOP Order
Calculate DOP Cost
Gantt Chart

1. You can either use the DOP from the previous exercise and skip to step 13, or follow the steps below.
2. In the DOP Header window, create a new record for part 22-110, a quantity of 2, due approximately one week from today.
3. Save your changes. Note the DOP ID:_______.
4. Create the structure from the default BOM or by selecting structure and routing values.
5. Optionally, net parts for various DOP orders in the structure from other DOPs or from inventory.
6. Release the entire DOP.
7. In the DOP Order window, query for the DOP ID. Select DOP Order ID 1, which is the order for part 22-110.
8. In the Supply tab, select the record in the table area, right-click and then click Go to Supply to open the pegged shop order.
9. Perform operations on the shop order by right-clicking and then clicking different options, such as Release, Material Actions, then Issue, and Report.
10. When reporting, you can choose to report more or less than the default quantity to report. You can also choose to scrap parts.
11. In the Calculate DOP Cost window, enter this DOP ID and select Standard, Estimated, and Actual, then click OK to run the costing process for this DOP.
12. Note that this is a background process and it may take a moment to complete.
13. Click the Gantt Chart tab.
14. The right side of the Gantt chart displays a horizontal activity bar for each DOP order in the structure.
15. The length of the activity bar is based on the revised start date and the revised due date.
16. If the structure has been netted or released with pegging, supply orders will also be displayed beneath their associated DOP order.
17. The supply order can be a shop order, purchase requisition, purchase order, a netted DOP order, or an inventory reservation.
18. The critical path for the DOP structure is computed and displayed.