Initial Exercises—Dynamic Order Processing 2

Basic Data Setup

Overview of Make To Order Data

Purpose: You need to do this exercise only once to support all Make to Order exercises in the current database. If you are participating in instructor led courses, you will not set up this specified data until after the following initial exercises. If you are doing self-directed learning and want to complete the following initial exercises, you should first complete this linked exercise. 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.

Overview of Make To Order Data lesson

Initial Exercises

Purpose:  The purpose of these initial exercises is for the instructor to use them to demonstrate the basic functionality in Dynamic Order Processing. These exercises are divided into two exercise documents which should be completed sequentially before going on to the various key exercises. This second portion includes:

• Resolving DOP Alarms

• Calculating DOP Costs

• Comparing DOP Structures

• Analysis of DOP Orders

Resolving DOP Quantity Alarms

Purpose: The purpose of this exercise is to introduce you to the basic functionality for resolving quantity alarms. The system can be set to generate alarms that will indicate if the supply is for a smaller quantity than is required for the DOP order.

Prerequisites: To demonstrate this functionality, you must have existing DOP orders with supply that is not available in sufficient quantity. In this exercise, we will demonstrate a scenario involving insufficient quantity.

Windows:
DOP Order
Generate DOP Alarm
DOP Header/Tree Structure
DOP Order/Tree Structure

Steps: To complete this exercise, perform the following steps.

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 3 to 2. Save your changes. Click Yes in the dialog box asking if you want to re-plan.
3. In the DOP Order window, right-click and then click Specific Order Alarm Generation.
4. This will create the alarm record, which can be viewed in the Alarms tab. You may need to re-query the record. The source of the alarm is shop order, it is a quantity alarm with a shortage of 1. (You can also see that the Alarm Exists check box is selected in the Details tab.)
5. Optionally, you can acknowledge that you have seen this alarm, by right-clicking and then clicking Acknowledge. This status can be used later in queries.
6. There are two ways to resolve the shortage in this window, using the right mouse button options, either by netting or increasing the quantity on the shop order. Select the alarm record, and right-click and then click Increase Quantity.

Note: You will not be able to do this if the shop order has been started.

7. To view the changes in the shop order, right-click and then click Go to Source. Note that the lot size is now 3.

8. Return to the DOP Order window, and run the alarm generation again (right-click and then click Specific Order Alarm Generation). You may need to re-query the record to see that the alarm has been resolved and the alarm record has been removed.

9. Another way to resolve a quantity alarm is to create a new pegged order.  On the DOP Order/Detail tab or the DOP Header/Structure tab, right-click and then click Create Pegged Order to create another pegged order for the additional amount required.

Resolving DOP Date Alarms

Purpose: The purpose of this exercise is to introduce you to the basic functionality for resolving date alarms. The system can be set to generate alarms that will indicate if the supply is due later than is required for the DOP order.

Prerequisites: To demonstrate this functionality, you must have existing DOP orders with supply that is not available by the required date. In this exercise, we will demonstrate a scenario based on a late shop order.

Windows:
DOP Order
Generate DOP Alarm
DOP Header/Tree Structure
DOP Order/Tree Structure

Assume that due to limited shop floor capacity, the supplying shop order need date has been changed. You will make changes in the system to reflect this. We will use this simulated delay to generate an alarm to resolve.

1. Using the same DOP order from above, note the date in the Revised Due Date field in the Details tab:___________.
2. Click the Supply/Summary tab. Select the record for shop order supply type. Click and then right-click Go to Supply. This will open the associated shop order.
3. In the Shop Order window, add seven days to the date in the Need Date field, and save the record. Click Yes in the dialog box to replan the DOP order.
4. In the DOP Order window, right-click and then click Specific Order Alarm Generation. This will create the alarm, which you can view in the Alarms tab. You may need to re-query the record. The source of the alarm is shop order, it is a time alarm with a delay of 7. (You can also see that the Alarm Exists check box is selected in the Details tab.)
5. Optionally, you can acknowledge that you have seen this alarm, by right-clicking and then clicking Acknowledge. This status can be used later in queries.
6. There are two ways to resolve the delay in this window, using the right mouse button options. To automatically change the need date in the shop order, select the alarm record, and right-click and then click Adjust Date. Right-click and then click Go to Source to open the shop order. Select the Schedule Shop Order right mouse button option. This will change the start and finish dates. 
7. Alternatively, you can manually adjust the need date in the shop order by right-clicking and then clicking Go to Source, and then clicking Yes in the dialog box asking if you want to re-plan.
8. Return to the DOP Order window, and run the alarm generation again (right-click and then click Specific Order Alarm Generation). You may need to re-query the record to see that the alarm has been resolved and the alarm record has been removed.

Calculating DOP Costs

Purpose: The purpose of this exercise is to introduce you to the basic functionality for calculating costs for all sites, per site, or DOP ID for standard, estimated, and/or actual costs. You will also see how to view cost variances.

Prerequisites: To demonstrate this functionality, you must have existing DOP orders which are released to create shop orders.  You also need to have reported time or quantity or reported scrap on these shop orders. In this exercise, we will demonstrate how to view the costs for a DOP ID.

Windows:
Calculate DOP Cost
DOP Header/Costing
DOP Order/Costing

1. In the DOP Header window, query for your DOP ID which has been released and whose pegged shop orders have some quantity or time reported.
2. In the Costing tab, right-click and then click Calculate DOP Cost to open the Calculate DOP Cost dialog window.
3. The DOP ID field will default with your DOP ID value.
4. Select the Standard, Estimated, and Actual check boxes, and then click OK.
5. Note that this is a background process and it may take a few moments to complete.
6. Re-query your DOP ID to view the results in the DOP Costing tab.
7. Note that this process can also be started from the Calculate DOP Cost window.
8. You can choose to schedule this as a job which will run at specified times on specified days.
9. You can choose to run the process for all sites, a specified site, or a specified DOP ID.

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 above.

Prerequisites: You will use the second customer order line you created in the first exercise above. Structures and routings for the specified part(s) in the DOP header must already exist.

Windows:
Customer Orders
Compare DOP Order and BOM
Comparing DOP Structures
Monitoring Cost Performance

1. In the Customer Order window, query for the order you created in the first exercise above.
2. Click the DOP Info tab. In the Line No list, click the record for delivery number 2 (Del No 2).
3. In the table area, select the line and right-click and then click DOP Header Detail to open the associated DOP header record.
4. In the DOP Header window, click in the header area or the Detail tab, and right-click and then click Create DOP Structure, and then click Create DOP Structure.
5. In the Create DOP Structure/Routing window, click in the Structure Alternative No field, click List to select alternative structure 1, and then click OK.

Note: You do not need to net or release the DOP header to be able to make the following comparisons.

6. Open the Compare DOP Order and BOM window and populate or query for your DOP ID. If necessary, select your DOP ID from the list in the DOP ID field. 
7. In the Part No field, select 22-110 to compare your DOP structure to the standard bill of material for the part.
8. Click All, Equal, and Difference to view, respectively:
   • The entire structures of both the DOP and the BOM.
   • The parts of the structures that are the same,
   • The parts of the structures that are different.
9. Click Tree after clicking each of the above choices to compare the structures in a graphical view.
10. Open the Comparing DOP Structures window. Populate or query for your two DOP IDs.
11. In the Comparator section, click one of your DOP IDs from the DOP ID list. Select the other DOP ID in the DOP ID field of the Comparatee section.
12. 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.

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: You must have run the DOP cost calculation process for a DOP ID that has been released with at least one pegged shop order having time or quantities reported.

Windows:
Monitoring Cost Performance
DOP Header/Performance Monitoring

1. In the Monitoring Cost Performance window, query for the DOP ID from the Calculating DOP Costs exercise above.
2. By referring to the Legend in the graph area, you can see different performance, cost, and value graphs for this DOP ID.
3. Note that you can also view this information in the DOP Header/Performance Monitoring tab.
4. To generate information and create visual presentations, right-click and then click the following options: Calculate DOP Cost, Copy, Print, Save Graph As, and Reset To Default.