Generating DOP Alarms—Key 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

Purpose: The purpose of these exercises is to see how situations such as quantity and date mismatches between supply and demand, are identified by the DOP alarm functionality.

Quantity Alarms Between Customer Order and DOP Header

Purpose: The purpose of this exercise is to create a situation where the quantity of a DOP Header does not match the quantity of a customer order line to which it is pegged.

Windows:
Customer Order
 DOP Header
Alarms

  1. In the Customer Order window, create a customer order line for part 22-110, for a quantity of 3, due in approximately one week.  Release the customer order to automatically create a DOP header.
  2. In the DOP Header window, create the structure and release the DOP header.
  3. In the Customer Order window, change the quantity from 3 to 5 and do not replicate the changes to the DOP header.  Refer to the the Replicate Changes Between Customer Orders and DOP Headers lesson for more information on this.
  4. In the DOP Header window, click the Alarms tab. Verify there is a quantity alarm with a source of CustomerOrderDemand. This alarm indicates the DOP header is short of a quantity of 2 for the customer order line to which it is pegged.
  5. Highlight the record, right-click and click Update DOP Header Qty Demand. A message displays to ask whether the pegged order should be updated.  Respond with Yes.
  6. The quantity alarm is removed.
  7. Click the Detail tab in the DOP Header window.  The qty demand is changed to 5.
  8. Change the qty demand from 5 to 3.
  9. Click the Alarms tab.  Verify there are two quantity alarms, one with a source of CustomerOrderSupply and another with a source of DopHeader.  The CustomerOrderSupply alarm indicates there is a shortage for a quantity of 2 between the DOP header and the customer order lines to which it is pegged.  The DopHeader alarm indicates there is an excess for a quantity of 2 between the top DOP order and the DOP header.  Highlight the CustomerOrderSupply record, right-click and click Update DOP Header Qty Demand.  Respond with Yes to update the pegged order.
  10. Both of the alarms are removed.

Quantity Alarms Between Supply Order and DOP Order

Purpose: The purpose of this exercise is to create a situation where a pegged order will not be able to supply a sufficient quantity to a DOP order.

Windows:
DOP Header
DOP Order
Shop Order/Detail

  1. In the DOP Header window, create a DOP for part 22-110, for a quantity of 5, due in approximately one week. Create the structure and release the DOP.
  2. Once the release process finishes, re-query your DOP ID in the DOP Header window. Click the Structure tab. In the table area of the tab, find the order for part number 22-210. Select this record. Right-click amd then click DOP Order Detail to open the DOP Order window.

Assume that the shop order has been changed by someone on the shop floor. You will make changes in the system to reflect this. We will use this shortage to generate an alarm to resolve.

  1. In the DOP Order/Supply/Shop Order tab, right-click and then click Shop Order Detail. This will open the Shop Order window.
  2. In the Lot Size field, change the quantity from 5 to 4. Save your changes. A message displays to ask whether to replicate the change to the DOP order.  Respond with No.  A second message displays to ask whether to replicate the change for the pegged DOP parts. Respond with No. Refer to the the Replicate Changes Between Pegged Orders and DOP Orders lesson for more information on this.
  3. In the DOP Order window, click the Alarms tab. Verify there is a quantity alarm with a source of DopOrder.  This alarm indicates there is a shortage for a quantity of 1 between the DOP order and its pegged supply orders. (You can also see that the Alarm Exists check box is selected in the Details tab.)
  4. In the DOP Header window, re-query for your DOP ID.
  5. Click the Alarms tab in the DOP Header window. All alarms for all orders for this DOP are listed by DOP order number. You can use right mouse button options to go to the DOP order with the alarm or to the source of the alarm.
  6. Click the Structure tab. In the table area, right-click and then click DOP Order Detail to open the DOP Order window for the top order.
  7. Click the Component Alarms tab to view the alarm for components of this DOP order.
  8. In any of the windows that you have viewed the alarm, you can right-click and then click Acknowledge to set the status of the alarm to Acknowledged. This status can be used later in queries for grouping alarms.
  9. Highlight the alarm record, right-click and click Adjust Quantity.  The alarm is removed.
  10. In the Shop Order window, verify the lot size of the shop order is changed back to 5.

Time Alarms Between Customer Order and DOP Header

Purpose: The purpose of this exercise is to create a situation where the due date of a DOP Header does not match the planned due date of a customer order line to which it is pegged.

Windows:
Customer Order
 DOP Header
Alarms

  1. In the Customer Order window, create a customer order line for part 22-110, for a quantity of 3, due in approximately one week.  Release the customer order to automatically create a DOP header.
  2. In the DOP Header window, create the structure and release the DOP header.
  3. In the Customer Order window, change the wanted delivery date from one week to two weeks from today and do not replicate the change. 
  4. In the DOP Header window, click the Alarms tab. Verify there is a time alarm with a source of DopHeader. This alarm indicates the DOP header has a due date which is 7 days earlier than the customer order line to which it is pegged.
  5. Highlight the record, right-click and click Update DOP Header Due Date. A message displays to ask whether the pegged order should be updated.  Respond with Yes.
  6. The time alarm is removed.
  7. Click the Detail tab in the DOP Header window.  The due date is changed to two weeks from today.
  8. Change the due date to one week later than its current date.
  9. Click the Alarms tab. Verify there are two time alarms, one with a source of DopHeader and another with a source of DopOrder.  The DopHeader alarm indicates the DOP header has a due date which is 7 days later than the customer order lines to which it is pegged.  The DopOrder alarm indicates the top DOP order has a due date is 7 days earlier than the DOP header. Highlight the DopHeader record, right-click and click Update DOP Header Due Date.  Click Yes to the message that appears to update the pegged order.
  10. Both alarms will be removed.

Time Alarms Between Supply Order and DOP Order

Purpose: The purpose of this exercise is to create a situation where a pegged order will not be able to meet the date of  the DOP order.

Windows:
DOP Header
DOP Order
Shop Order/Detail

  1. In the DOP Header window, create a DOP for part 22-110, for a quantity of 5, due in approximately one week. Create the structure and release the DOP.
  2. Once the release process finishes, re-query your DOP ID in the DOP Header window. Click the Structure tab. In the table area of the tab, find the order for part number 22-210. Select this record. Right-click amd then click DOP Order Detail to open the DOP Order window.

The shop order, for some reason, has been replanned. Simulate this by changing the shop order’s need date to a date later than one working day past the DOP order’s due date.

  1. In the DOP Order/Supply/Shop Order tab, right-click and then click Shop Order Detail. This will open the Shop Order window.
  2. In the Need Date field, change the date from one week to two weeks from today. Save your changes. A message displays to ask whether to replicate the change to the DOP order.  Respond with No.  A second message displays to ask whether to replicate the change for the pegged DOP parts. Respond with No. Refer to the the Replicate Changes Between Pegged Orders and DOP Orders lesson for more information on this.
  3. In the DOP Order window, click the Alarms tab. Verify there is a time alarm with a source of ShopOrder.  This alarm indicates the revised due date of the shop order is 7 days later than the revised due date of the DOP Order.
  4. Highlight the alarm record, right-click and click Adjust Date.  The alarm is removed.
  5. In the Shop Order window, verify the need date of the shop order is changed back to one week from today.

Note: When the supply order is a purchase order and there is a difference between the planned receipt date of a purchase order line and the revised due date of a DOP order, the source of the time alarm is PurchaseOrder.  When the supply order is a purchase requisition and there is a difference between wanted receipt date of a purchase requisition line and the revised due date of a DOP order, the source of the time alarm is PurchaseRequisition.

Routing Revision Alarm

Purpose: The purpose of this exercise is to create a situation where a date change for a DOP order affects its routing revision.

Windows:
Routing
 DOP Header
DOP Order

  1. In the Routing window, query for part 22-210.  Change the Phase Out Date to the next day.
  2. Create a new Routing Revision with a Phase In Date to two days from today.
  3. Copy the Routing from revision 1 to the new revision. Increase all of the machine run times by a factor of 2.
  4. Use an existing DOP header for part 22-110. In the DOP Header window, click the Structure tab. In the table area of the tab, find the order for part number 22-210. Select this record. Right-click and then click DOP Order Detail to open the DOP Order window.
  5. Modify the revised start date to one week from today.
  6. Click the Alarms tab.  Verify there is a Routing Revision alarm with a source of DopOrder.  This alarm indicates the current routing revision set of the DOP order is not in effect on its revised start date.
  7. Highlight the record, right-click and click Go To Source.
  8. In the DOP Order window, right-click and click Change Routing Revision and/or Alternate. Select the new revision.  A message displays to indicate the DOP order and pegged shop order are updated with the new routing.
  9. Click the Alarms tab to verify the routing revision alarm is removed.

Note: When the structure revision set for a DOP order is not effect on its revised start date, a structure revision alarm is created.  In order to resolve the alarm, choose a new structure revision  with the Change Structure Revision and/or Alternate option for a DOP Order.

Running Alarm Generation as a Scheduled Job

Purpose: The purpose of this exercise is to show how to set up alarm generation to run as a scheduled job.

Windows:
Generate DOP Alarm
Runtime Monitoring/Server Processes

  1. Open the Generate DOP Alarm doalog box.
  2. Select the desired values in the Parameters area. For example, select the All Sites check box or select a value in the Site field from the List of Values. You can also select a specific DOP ID. You can choose only one of these three.
  3. Optionally, you could click OK to run this immediately, but instead, we want to have this process run at a specific time on specific days of the week.
  4. Click Schedule.
  5. You can also open New Database Task Schedule and select Generate DOP Alarms as the database task.
  6. For this exercise, select the Activate check box in the right hand side of the window to activate the task.
  7. Save.

Note: You need to use the Generate DOP Alarm window or create a schedule for each different time during the day you want the process to run. If you want the process to run for different sets of parameters, for example for more than one site but not all sites, or more than once per day, you will need to use the Generate DOP Alarm window or create a new schedule task for each set of parameters.

Configuration Alarms Between Customer Order and DOP Header

Purpose: The purpose of this exercise is to create a situation where the configuration used to create the DOP structure does not match the configuration of a customer order line to which the DOP Header is pegged.

Windows:
Customer Order
DOP Header
Alarms

  1. In the Customer Order window, create a customer order line for part 22-110, for a quantity of 3, due in approximately one week. Release the customer order to automatically create a DOP header.
  2. In the DOP Header window, create the structure and release the DOP header.
  3. In the Customer Order window, change the planned delivery date on the customer order line so that a previous base part revision becomes effective. Reconfigure the configuration on the base of this part.
  4. In the DOP Header window, click the Alarms tab. Verify there is a configuration alarm with a source of DopHeader. This alarm indicates that the configuration defined for the DOP header does not match the configuration defined for the customer order line to which it is pegged.
  5. Highlight the record, right-click and then click Update Supply Configuration. Click Yes on the message that appears.

Note: There are two ways to handle a configuration alarm. If you select Update Supply Configuration then the changed configuration is promoted to the DOP header from the customer order line. The DOP structure is rebuilt completely considering the changed configuration and possible new requested planned delivery date/time defined for the customer order line. If you click Unpeg Customer Order Line then the DOP header is unpegged from the customer order line and the changed configuration is not promoted to the DOP header. The unpegged DOP header can either be canceled or processed. If processing the unpegged DOP header, the original configuration will be manufactured/purchased and delivered in to stock.

  1. The configuration alarm is removed.
  2. Right-click in the DOP Header window, point to Configuration and then click View. The base part revision used is now the same as the one used to reconfigure the configuration on the customer order line, due to the change of the planned delivery date. Possible changes of the characteristic record have also been updated.
  3. Click on the Structure tab. Verify that the DOP structure has been rebuilt completely taking into consideration the redefined configuration.

Note: The DOP alarm type configuration cannot be ignored or acknowledged. It must be solved before processing the DOP header and connected DOP orders. This means that all shop orders, purchase requisitions and purchase orders are locked and cannot be processed before the alarm is solved.