Below is a list of tips and tricks for the Make To Order course. Click the items below to see information that may be helpful to you as you complete the course:
It is extremely important that you set up and work within your own site to maintain 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 each student's data be isolated in a unique site. The site you create should be linked to company 10.
If you have not created your own site in the current course database, see the general exercise for Site for instructions.
To ensure that students have customers, parts, routings, structures, and other information set up correctly, they should complete the Overview of MTO Manufacturing Data lesson. This lesson provides step-by-step directions for copying the data to their site.
If you are an instructor, additional information is available about the Racing database, which is the database used by all IFS Training Materials.
The Racing database contains different data layers, including the following two layers that form the foundation of the database:
To see more information about the Racing database, including a link to documentation for the RTUBE data layer, see Racing Database in IFS Training Help.
If you try to release DOP headers or orders and you get the error message, 'Structure revision and alternative are required for a shop order,' one of the quickest ways to look for the problem is to look in the DOP Header/Structure Multilevel tab. Look at the following fields for each of the DOP structure levels: Part No, Create Pegged = Pegged Orders, Structure Alternate Status=NULL or not equal to Buildable, Part Type = Manufactured.
If there are records like this, the problem is that the DOP release process is trying to create a pegged shop order without a structure. Query for the part in the Product Structure window to see if there is a structure for the part, and if it is buildable. Look at the phase in and phase out dates and make sure that the due date for the DOP order falls within the phase in/out date range.
You can go to the supply detail records (e.g., shop order, purchase requisition, purchase order) from the DOP Order/Supply or Tree Structure tabs, the DOP Header/Tree Structure tab, and the DOP overview windows by using right mouse button options. These options include: Go To Supply, Shop Order Detail, Purchase Order, and Purchase Requisition Line. Linking to these supply records is only available if the supply type is included in the executable (e.g., shop order, purchasing)
The Configuration right mouse button options in the DOP Header and DOP Header/Detail tab are only available for configured parts, and only if the configuration modules are included in the executable.
You can quickly find customer orders tied to DOP orders by querying or populating the DOP Demands window. The customer order number is visible in the Order No field. To view the customer order, select the record and then right-click Customer Order. You can also right-click DOP Header Details to go to the associated header record.
Likewise, in the Customer Order/DOP Info tab and the Shop Order/DOP Info tab, you can select the DOP ID record, and right-click DOP Header Detail to go to the associated header record.
The Allocate and Netting settings on the DOP Header are propagated as defaults to all associated DOP orders. These settings can be changed on the separate DOP orders.
The DOP header shows the furthest status progress of any of the associated DOP orders. For example, if any DOP order in the structure is netted, the header status changes to Netted. If any DOP order in the structure is released, the header status changes to Released.
If logs exist for any DOP orders in the structure, the Log Exists check box will be selected on the DOP Header/Details tab, and all logs for the associated orders will be listed on the DOP Header/DOP Log tab.
If alarms exist for any DOP orders in the structure, the Alarm Exists check box will be selected on the DOP Header/Details tab, and all alarms for the associated orders will be listed on the DOP Header/Alarms tab.
You can redo an explosion (i.e., modify a structure by recreating it) in several places in the system, by right-clicking and clicking Change DOP Structure, and then selecting Change Structure Revision and/or Alternative. This option is available in the DOP Header/Structure and Tree Structure tabs, and in the DOP Order header and the DOP Order/Details and Tree Structure tabs.
Possible reasons for modifying a structure:
You cannot click Remove on the toolbar to directly delete a DOP from the DOP Header/Structure tab or the DOP Order/Components tab. The order to be deleted should be Created, Unreleased or Netted, and should not have any children/sub-components to simplify this operation.
If the order has children, you have to cancel, then delete each of the child orders before you can cancel and delete the parent order. Note that the parent order to be deleted also must have the Create Pegged option set to No Pegged Orders.
You also can accomplish this whole process by right-clicking and clicking Remove Specific Branch(es).
The concepts of upstream and downstream can be confusing, for example, when propagating date and quantity changes after you have changed them on any portion of the DOP structure. In graphical views, "child" or component parts/orders are shown below "parent" parts/orders; however, in terms of supply, they are upstream from the parent parts.
Propagate upstream means changing the dates and/or quantities on all the orders that supply the specified DOP order. These are the child parts or components that must be available on time, and in the correct quantity to be able to complete the specified DOP order. For example, if you have decided to add a full-size spare tire assembly consisting of a rim, a tire, and a valve stem, during vehicle assembly, then you need to propagate this increase in quantity upstream from the wheel assembly to each of the component parts, so you will have 5 tires, 5 rims, and 5 valve stems. The same concept applies if you are changing the dates. You need to propagate the date upstream to ensure that all the component parts will be available on time for the new date of the specified part.
Propagate downstream means changing the dates and/or quantities on all the orders that are supplied by the specified order.
DOP does not handle Byproducts (qty per assembly < 0) contained in the BOM structure. These parts are simply ignored when the DOP structure is created. DOP can though handle Expense Parts (qty per assembly = 0) contained in the BOM structure. These parts are included when the DOP structure is created.
If the site you are using has the purchase component method defined as supplier material, all parts that are purchased with a buildable structure will have that structure on the DOP order. This structure is linked to either the purchase requisition or the purchase order on the respective DOP Info/DOP Material Supply tabs.
To verify or change the settings for your site, open the Site window, and select the record for your site. In the Purchase Component Method field, select Supplier Material, and save the record.
If the site you are using has the purchase component method defined as customer order, an informational message will appear when you save the DOP header. Simply acknowledge this message by clicking OK.
If a purchase part's supply type is set to Requisition, a purchase requisition will be created when the DOP order is released. If a purchase part's supply type is set to Order, a purchase order line will created when the DOP order is released. In this case, you must have a supplier specified for the purchase part.
To verify or change this setting for the purchase part, open theInventory Part/Planning Data tab and view or change the value in the Supply Type field.
The quantity required of a component is calculated as the quantity of components per parent part (quantity per assembly) times the parent quantity. Because of shrinkage, this quantity must be increased by a factor which is calculated from an estimate of the standard percent shrinkage. If there is also a fixed number of component parts scrapped each time an order is processed, you must add this fixed scrap to get the final required quantity. The fixed scrap could be due, for example, to the parts destroyed during the setup process. The equation is shown below.
Component quantity required = ((parent quantity * quantity per assembly) / (1 - (shrinkage factor / 100))) + component scrap
DOP Info tabs are visible in the Shop Order and Customer Order windows only if Dynamic Order Processing is included in the executable.
Any part can be used when creating a DOP header, but you need a buildable structure to process the DOP header record.
The DOP connection and supply type set on the inventory part will default to the customer order line, but these values can be changed.
Blow-through parts (Inventory part planning method K) are blown through to (replaced by) their components. In the case of phantom parts (Inventory part planning method P), the program will check to see if phantoms are available to use. If not, they will be blown through to (replaced by) their components.