Order Module allows manufacturing to enter, edit, and print in house work
orders to build to stock. The work order contains valuable information such as has it been issued to manufacturing and how many assemblies
have been completed and returned to the stock room. It is important to note
that order entry sales orders automatically become work orders and share the
same database file. The Sale Order Form and the Work Order Form are same form
except that Work Order will take only one line item, 00WO and is labeled Work Order instead of Sales Order. Work Orders
are closed by: issuing the work order ( through the
Stockroom Module) to manufacturing and
receiving the finished assemblies back from manufacturing. Sales Orders are closed by issuing invoices.
13.1.2 New (Enter A New Work Order)
Work Order Data Entry Screen will appear:
Note: (at the
lower left hand corner) the Root Address and Part number check
boxes are activated (with check marks). This
indicates that the screen is set to look up address and part information from
Step 1: Select Customer:
Step 2: Select Part
Step 3: Enter Quantity
Step 4: Enter Date Required
Step 5: Enter the rest of the fields
Step 6: Save the Work Order when finished
Note: pc/MRP will check all the data validity. If the Customer Account # or Part Number is not valid (cannot be found in the Address Book or Part Master), the user will be prompted to take corrective actions.
The selections of the "Auto Look-Up Returns will determine what appear in the customer list and the part number list during the selecting customer and selecting parts operations.
Notes: When a work order is entered pc/MRP increments the ondemand quantity for the completed assembly and not the parts in that assembly. The explosion is done later in a temporary scratch pad field whenever purchasing runs an MRP Report. The MRP Report takes each assembly's on demand quantity and allocates finished on hand assemblies and subassemblies and finally parts to fill the demand. When it runs out of parts or goes below the minimum quantity level it prints out that part number and the quantity to purchase.
The above method provides pc/MRP with the following advantages:
* The on-demand
status of any assembly is available
* Line items can be quickly entered w/o waiting for an explosion
* You can build to stock, stocking finished-assemblies and sub-assemblies
13.1.3 Edit/View (Scroll/Delete/Undelete Work Order)
This option allows users to scroll, edit, delete, undelete or run queries against work order records.
Selecting an Indexed Search allows users to search on indexed fields. This allows pc/MRP to find the information much faster. To perform an Indexed Search select the:
· Indexed Search tab
· Desired Sort Order
· Desired Include information
· Enter the applicable data in the Begin Scrolling At: field
· Select the desired Action, View or Edit
· Press Search
pc/MRP will automatically scroll to the desired record or the nearest match. Select the correct record by scrolling and press Ok to proceed to the edit screen for that record.
Selecting to run a Queried Search allows users to build, run, save, and load queries for the work order table. For further details see chapter 15.14.
All of the fields in a work order are editable. Users however must understand several key concepts before editing work orders.
o If you were to edit the quantity on a work order you must also edit the quantity on order in inventory or run one of the Audit OnDemand features.
o The ISSUED / QTY ASSMD appear on the edit screen for work orders. pc/MRP will automatically enter a "Y" when the assemblies are issued from stock to manufacturing. The QTY ASSMD field is automatically updated when the assemblies are received by the stock room from manufacturing for that sales order number.
o The COMPLETE field is displayed only in the edit mode and is filled in automatically when the items are received back from manufacturing. pc/MRP uses the COMPLETE field to determine if a record is overdue, open or closed. A “Y” in the COMPLETE field marks the record as closed. An “N” in the COMPLETE field marks the record as open.
o The CO# stands for Change Order Number, this is used to note any changes in the order.
o Use the delete button to mark a record for deletion Once the record has been marked for deletion you must return to the menu and select REMOVE MARKED RECORDS.
13.1.4 Print (Display A Work Order)
Allows you to print out or display a work order.
13.1.5 Reports (Printout/Display Work Order Reports)
Allows you to print out or display various Work Order Reports. See section 15.4.1 to create custom reports. Your standard report options are as follows:
RECORDS (OPENED AND CLOSED)
ALL RECORDS FOR A SPECIFIED PRODUCT CODE
ALL RECORDS FOR A SPECIFIED PART NUMBER
ALL RECORDS FOR A SPECIFIED ACCOUNT
ALL RECORDS FOR A SPECIFIED ACCOUNT AND TIME PERIOD
ALL RECORDS FOR A DIVISION FOR A SPECIFIED TIME PERIOD
ALL RECORDS DUE ON A SPECIFIED TIME PERIOD
ALL CASH RECORDS FOR A SPECIFIED DAY
ALL OPEN RECORDS (Backlog and Mfg Schedule
ALL OPEN RECORDS FOR A VEND/CUST ACCOUNT #
ALL OVERDUE RECORDS
Any of the above may include the following:
Matching Exact: This selection allows you to find a work order report by using the exact work order report record, specified day, specified period of time, specified product type, specified part number, specified account, specified account and time period, division for a specified time period, due date on a specified time period, specified day, open records, open records for a vend/cust account #, or all overdue records. It will display/print/send only that record.
Matching Partial: This selection allows you to find a work order report by using a partial description of the exact work order report record, specified day, specified period of time, specified product type, specified part number, specified account, specified account and time period, division for a specified time period, due date on a specified time period, specified day, open records, open records for a vend/cust account #, or all overdue records. It will display/print/send all work order reports matching the partial description.
Any of the above may be sorted by:
Part Number Root
Date Required (Manufacturing Schedule)
Re-indexes the Sales/Work Order index file. pc/MRP automatically updates its index files under normal operation. However, if you ever get a "record out of range" error message or can not find a sales or work order, re-indexing the index file is usually the cure.
13.1.7 Remove Marked Records
Removes all of deleted Sales/Work Orders from the disk. The records will no longer be recoverable.
13.1.8 Remove Over X Years
Deletes and removes from the disk all Sales/Work Orders over a specified number of years old. Prior to running this command it is advisable to save the Sales Order Database File to disk and label it "Sales DBF as of mm-dd-yr". You should also generate a printout of the file prior to closing it out.
13.1.9 Summary of Flag Files
If the flag file SHORTRTN.FLG exists work orders returned from manufacturing short will prompt users to decide if the order should be closed automatically or remain open.
13.1.10 Dedicated Work Orders (pc/MRP Versions 7.83 and higher)
To create a parent sales or work order, you must check its Requires Dedicated Work Orders check box, as shown below:
To create dedicated work orders, you must enter the sales/work order number it is dedicated to, as shown below:
13.1.11 Dedicated Work Orders Rules (pc/MRP Versions 7.83 and higher)
A top dedicated sales or work order cannot have a duplicate twin work order for the same assembly(s) reporting to it. The Infinite Bucket Module will not use the twin work order and insert an error message into the MRP Error Log asking you to delete the twin work order and re-generate the MRP. All work orders dedicated to a top parent work order must be sub-work orders, as shown in the figure above.
All sub-work orders must regardless of level must be dedicated to the top parent sales or work order.
Once a sales or work order has been issued to manufacturing, you cannot change its dedication fields.
Dedicated sub-work orders for the lowest level assemblies must be issued first and received back from manufacturing before the next level up sub work orders can be issued to manufacturing. Failure to do so, could cause pc/MRP’s Infinite Bucket Program to generate error messages notifying you it created un-attached make action items. You would have to un-issue the work order and re-generate the MRP to correct the situation(s).
The dedicated sub work orders must have a date-required field that is prior to the date-required field on its parent sub-work order. If not pc/MRP, will insert an error message into the ‘MRP Error Message Log’ and the ‘Make Push Pull Report’, warning you that the date-required should be changed. pc/MRP will generate the MRP on the basis of its recommended date, hoping that you will change the work order’s date required and issue it on the date listed on the action item report.
A dedicated top parent work order cannot be dedicated to another sales order or work order.
All dedicated sub-work orders are consumable but will only be used by the top parent work order or another work order dedicated to the same top parent work order.
13.1.12 How pc/MRP’s Infinite Bucket Module processes dedicated work orders
When generating an MRP, pc/MRP will first check that the date required on all dedicated sub-work orders are correct. If the date(s) required are not correct, it will insert an error message into the MRP Error log and the Make Push Pull Report warning you to change the date(s) required. It will then use the correct date(s) required and generate an MRP.
When allocating sub-assemblies to dedicated sales or work order, pc/MRP will first allocate from the on hand quantity of the sub-assembly. If more are required, it will allocate from sub-work orders dedicated to the same top work order or from non dedicated consumable work order (based on which work order has the earliest date due). Finally, if it cannot allocate a sufficient quantity, it will insert an error message into the MRP Error Log warning you it created an unattached make for that assembly.
13.1.13 How pc/MRP’s Infinite Bucket Module processes un-dedicated work orders
pc/MRP’s Infinite Bucket Module was originally designed such that users could simply enter sales orders, generate an MRP, when ready, issue the top level sales order and all of its assemblies to a staging box or area. If there were shortages, pc/MRP’s Stockroom module and MRP program would prompt you to order the missing parts and issue them when they arrived. Work orders did not need to be created for sub-assemblies. Work Orders for Sub-assemblies did not need to be issued on set dates and received back on set dates so the next level up work orders could be issued. When running the Infinite Bucket Module, pc/MRP simply looked at the current situation and modified it’s Make action items to get the job done. If parts or sub-assemblies were used for another job it simply created new make or buy action items to fill the sales orders. Work orders were used primarily to build runs of common sub-assemblies and could be used for any sales order.
13.1.14 Additional error trapping code added to pc/MRP’s Issue to Mfg function
pc/MRP’s Stockroom Module’s I and L ‘Issue To Manufacturing’ functions will throw an error message and not allow the issue for the following conditions if you are issuing a dedicated sub-work order:
· If the top parent order does not exist
· If the top parent work order does not require dedicated work orders
· If the top parent work order is for the same part/assembly number
In addition, when issuing a dedicated sub-work order, pc/MRP’s Issue to Manufacturing function will only allow the user to select the Issue Sub-assemblies Only option.