Stockroom Module

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11.1    Overview of the Stock Transaction Module

 

The Stock Room Module allows users to: receive parts from receiving, issue parts and sub-assemblies to manufacturing, receive parts from manufacturing as completed assemblies, backflush piece parts, issue parts and assemblies to shipping, issue parts from one inventory area to another, and adjust the onhand quantities.

 

11.2.1  Issue parts/sub-assemblies to a sales or work order Step 1 – Press New

 

By Selecting Modules, Stockroom, and New pc/MRP will display a list of all of the stockroom transactions available for users to enter. Simply click on the radio button or press the key of the letter you want.  The user name, date, and time will be stored in the Entered By field for every transaction made.  Comments for each transaction are also available. Following is a description of each type of transaction.

 



 

11.2.2   Issue parts/sub-assemblies to a sales or work order Step 2 – Select Issue

 

 

Select the "I" transaction to issue a top-level assembly(s) infinite levels deep for a sales/work order.   You must use this function once and only once to issue parts for every sales/work order that is issued to manufacturing.

 

All manufacturing jobs start with the I (for issue) type transaction and end with the R (for receive) type transaction.  Users can only use the L, M, F, B, U, and T type transactions after performing the I transaction and before performing the R transaction.

 

Select the stock room area you wish to issue the parts from.  pc/MRP cannot issue from multiple areas during the I type transaction.  If a users wishes to issue part of the build from one inventory area and other parts from a different inventory area, users will have to issue the I transaction short, and perform make up transactions, M, F, and B, transactions to issue from the alternate area.

 

Enter the account number to credit for these parts if required to do so by accounting, otherwise leave this space blank (pc/MRP's accounting package does not use this field).

 

pc/MRP will display the next available stock transaction number. Press OK to accept the number.

 

Answer Yes, if there is a sales/work order number for this transaction. pc/MRP will then allow you to scroll by sales/work order number, part number, or account number for the correct sales/work order number.

 

Please Note: You must enter an existing Sales or Work Order Number; otherwise pc/MRP will not be able to decrement the WIP quantities correctly when the Sales/Work Order is received as assemblies from manufacturing.

 

11.2.3      Issue parts/sub-assemblies to a sales or work order Step 3 – Select Issue Methods

 



 

pc/MRP must be told how you want to issue the items. You can issue component parts only, sub-assemblies only or both part and sub-assemblies.

o        Never Ask, will issue sub-assemblies only.

o        Ask When Short, will ask to issue parts or subassemblies if subassemblies are short. If you select Parts, it will issue remaining sub-assemblies and then parts.

o        Always Ask, will ask to issue parts or sub-assemblies when it comes to a sub-assembly. If you select parts, it will issue parts.

 

By default, pc/MRP will automatically issue items. If you prefer to verify each item or record serial/lot numbers using pc/MRP's standard serial/lot number features, uncheck the "Issue parts automatically" check box.  If “Issue Parts Automatically’ is checked and Option 45 in Settings & Utilities is set to Issue Quantity Required instead of Issue Quantity Available, pc/MRP could drive On-hand quantities negative as if there is a shortage.

 

 

 

 

11.2.4  Issue parts/sub-assemblies to a sales or work order Step 4 – Select Line Items

 



 

 

 

Select the line items on this sales order you wish to include on the issue.   Line items that can not be issued and the reason they can not be issued will be displayed in the scrollable list box below the line item list.

  

11.2.4      Issue parts/sub-assemblies to a sales or work order Step 5 – Handle any Shortages

 



 

If you issue the parts one at a time instead of automatically or pc/MRP detects a shortage the screen shown above will be displayed.  Option 45 can be set to default the Qty Issued Field to the quantity required or the quantity available.    We recommend you set Option 45 to the Quantity Available and always inset the actual quantity issued (this will keep your WIP straight).    If you set Option 45 to Required, you do not answer ‘Yes’ to track serial numbers, and you have checked Automatic issue, the screen below will not appear and part quantities can be driven negative.

 

Always enter the correct quantity issued to the manufacturing floor.  pc/MRP will create an issue to manufacturing stock room record decreasing the stock room quantity and increasing the WIP quantity.   If you count the quantity left in the bin, it is different from the displayed quantity left, and you enter the correct quantity left in the bin, pc/MRP will make an additional adjusting stock room record.  

 

Whenever users enter an "I" type transaction, pc/MRP creates a stock transaction record for each part or sub-assembly issued. Each stock transaction record created contains the following fields:

 

11.2.6   Issue parts/sub-assemblies to a sales or work order Step 6 – Record Serial Numbers

 

If you have activated pc/MRP's Advanced Serial/Lot Number module, pc/MRP will ask if you wish to enter serial numbers. If the serial numbers entered are past their expiration date the user will be warned to cancel or continue.

 

Furthermore, if you have changed the QTY Left in the Bin field on the Issue Stock to Manufacturing screen, the serial lot number module has been activated, and the part is serialized, the Adjust Serial/Lot button will appear.

 


If you want to adjust serial/lot number, click the Adjust Serial/Lot button.  You will get a list of the existing serial lot numbers from the master serial lot number table for that part as shown on the Serial/Lot Number List Screen.  If you would like to enter a new serial lot number, click on the New button, you will get a screen similar to the Serial Lot Number Adjustment Screen.  Enter the necessary fields for the serial/lot number and click Ok to save.  If you would like to adjust the serial lot quantity for an existing serial lot number, select the serial lot number, and click the Edit button, you will get the Serial Lot Number Adjustment Screen.  Entering a negative number into the Adjust QTY field will bring the serial/lot quantity down and entering a positive number into the Adjust QTY field will bring the serial/lot quantity up.   Click the Ok button to save the adjusted serial lot number.  When you are done with entering and adjusting the serial lot numbers, click Ok on the Serial/Lot Number List screen.   All of the newly entered serial numbers will be saved into the master serial lot number table, and the adjusted serial lot numbers’ SNLOTQTY field in the master serial lot number table will be replaced by the value in the NEWSNLOTQTY field of the cursor.   An adjustment entry will be created in the detail serial/lot number table for each adjusted serial lot number.

 

11.2.7      Issue parts/sub-assemblies to a sales or work order Step 7 – Print PIC List/Labels

 



 

 

pc/MRP will produce an "Issued PIC List" report containing the details of all items issued. The report can be displayed, printed, or saved as a file.

 

In versions 7.50 and higher users can create a flag file allowing labels to be created for the items being issued to manufacturing. The flag file is isstklab.flg.

 

If this file is present in the pcmrpw directory the screen shown above will appear.

 

This option allows users to select various criteria, a specified work order, and multiple output types for the labels to be created.

 

11.3.1    L - Issue Part(s) and/or Assemblies one Level Deep to Manufacturing

 

Only use this function to issue extra parts or parts that were not on the bill of materials.   Select an "L" transaction to issue a part, or combination of parts and completed sub-assemblies for a  sales or work order to manufacturing.    You will be asked whether the information is to be manually entered or imported from an ASCII file. Manual entry is the most often used method and will be explained first.   pc/MRP will reduce the onhand quantities and increase the WIP quantities of the parts and finished sub-assemblies issued.

 

·         Select the stock room area you wish to issue the parts from.

·         Enter the account number to credit for these parts if required to do so by accounting, otherwise, leave this space blank.

·         pc/MRP will display the next available stock transaction number. Press OK to accept the number.

·         Answer Yes, if there is a sales/work order number for this transaction.

·         Enter the Part or BOM number and the quantity you wish to issue.

·         Enter Yes, if you wish to track lot numbers.

·         If the number entered was a BOM number, pc/MRP will ask if you wish to issue the BOM to the floor as a completed assembly or as component parts.

·         If you choose to issue as a completed assembly, pc/MRP will issue the assembly(s) as a completed assembly(s).

·         If you choose to issue the assembly as component parts, pc/MRP will issue the component parts. Once again enter the date and quantity of the assembly you wish to issue (pc/MRP will not change the onhand quantity of the assembly at this time).

·         Answer Yes, if you wish parts to be issued automatically.

·         When it comes to a sub-assembly for that kit, pc/MRP will ask "Issue parts or Sub-Assemblies?Answer G if you wish to issue the sub-assembly as completed sub-assemblies. Answer B if you wish to issue the sub-assembly as parts on another lower level "L" type transaction that you will enter after you have finished issuing parts at this level.

·         Creating a text file, LISSUPWO.FLG, with notepad in the pcmrpw directory will force pc/MRP to insert a ‘Y’ into the Sales/Work Order ISSTMFG field. This is not recommended, as pc/MRP will not allow an ‘I’ type issue transaction to that Sales/Work Order afterwards.

 

 

11.3.2 Importing Part Number and Quantity information

 

Importing creates a series of "L" type Stockroom transactions from a comma separated ASCII file. This file may be generated by a barcode reader or produced by another program. The ASCII file must contain the Part number and Quantity information and may contain other optional information.

The data structure of the ASCII file is shown below:

 

DATA

TYPE

  Part Number
  Quantity Issued
  SO/WO Number (leading zeros)
  SO/WO Item Number (leading zeros)
  Issue Area (same as area name)
  Lot Number
  Quantity Required

6-15 Character   Numeric
  6 Character (optional)
  4 Character (optional)
  8 Character (optional)
  6 Character (optional)
  Numeric (optional)

 

The following screen allows configuration of the import process.

 


·         Enter the location and name of the import file or use the FIND button to pick it from the directory tree.

·         Configure the Sales/Work Order info to meet your situation.

·         If all the items to be issued are against the same sales/work order, selecting Manual allows a one-time entry of the sales/work order number, which is then applied to all items issued.

·         Lot tracking has three possible settings:

·         Any of the eleven storage areas can be manually selected as the issuing area or it can be set to automatically draw the issuing area from the import file.

·         Pressing OK will begin the import process.

·         If any errors are detected during the importation process, an error report will be available after completion.

 

11.4   M - Issue Makeup or Shortage Parts to Mfg

 

We strongly recommend using the stockroom’s P option instead of the M or F option to issue makeup shortages to sales and work orders.

 

Enter the stock transaction number of the part that is short. The stock transaction number can be located on the stock transaction report for that sales/work order number.

 

pc/MRP will allow you to enter the lot number and the quantity required to fill the shortage. pc/MRP will then reduce the onhand quantities and increase the WIP quantities of the parts issued.

 

For stockroom transactions P, M, and F if option 66 in the settings and utilities is set to yes, the original transaction date will be replaced by the date of when the makeup shortage issue is performed.

For versions 7.71A an lower, pc/MRP increases the quantitu issued in the original stockroom transaction record.

 

With versions 7.71B and higher, pc/MRP will create a new issue transaction for makeup transactions and the quantity required will be reduced to equal the original quantity issued in the original stockroom record.. 

 

If the sales order is closed, pc/MRP will not allow you to issue a makeup issue against the order. 

 

 

11.5    F - Issue Multiple Makeup Shortages to Manufacturing Automatically

 

We strongly recommend using the stockroom’s P option instead of the M or F option to issue makeup shortages to sales and work orders.

 

Use this function to automatically issue make up shortages for items that were short when the original "I" type transaction was issued for a sales/work order number. It will fill as much of the shortage as the inventory level allows while giving priority to the sales/work orders by with the earliest date required. This function looks at shortages for open sales and work orders (complete does not equal Y) that have been issued (issuedtmf = Y) that now have stock available to be issued (onhand greater than 0).

 

The user may select the inventory area(s) to consider when issuing items. The user also has the ability to issue only to sales order transactions or work order transactions.

 

Two reports are available after completion. The Action report details all of the stockroom shortages that were filled. The Make-up shortage Pick list produces an inventory list of material from each inventory area to be transferred from inventory to WIP.

 

The user may elect to actually issue shortage make-ups or to simulate the shortage make-ups. Actually issuing will produce the reports described above while reducing the quantity of the parts from the issuing area and increasing the quantity in WIP. Simulating the shortage make-ups will produce the same reports as the actual issue without transferring inventory. This allows the user to check the shortage make-ups before they are transacted.

 

For stockroom transactions P, M, and F if option 66 in the settings and utilities is set to yes, the original transaction date will be replaced by the date of when the makeup shortage issue is performed.

 

11.6    P - Issue Multiple Makeup Shortages from a Single Inventory Area

 



 

The P option allows users to fill stock room shortages from a list of possible stockroom transactions that were issued short. When users select this option, pc/MRP will create the screen above. This screen allows users to select the criteria to generate the list of shortages to be filled.

 

·         The Issue Shortage Make-ups screen allows users to choose from a list of shortages that can be filled and fulfill them by entering the desired quantity to be issued.

·         For stockroom transactions P, M, and F if option 66 in the settings and utilities is set to yes, the original transaction date will be replaced by the date of when the makeup shortage issue is performed.

·         NOTE: The ‘P’ type transaction must have a positive quantity on hand in the chosen inventory area in order for the shortage to be displayed.

 

11.7.1    S - Issue Parts or Assemblies to Shipping

 

Enter an "S" to issue parts or assemblies to shipping.

 

 



 

 

pc/MRP will issue each line item as you have configured it on this screen. The onhand quantity of each part shipped will be reduced if pc/MRP is configured to do so in the configuration menu. (Do not use this transaction if you are set to Inventory Adjustment method A, see Settings and Utilities option 4.)

 

11.7.2    In the upper left corner of the window:

 

·         The Sales Order number against which the material is to be issued can be manually entered or you may elect to pull the number in by scrolling the Sales database.

·         This is where the Inventory area from which the material is to be issued is selected.

·         Users who have purchased the optional Serial/Lot Number module can elect to track the serial or lot numbers of the material that is issued.

 

11.7.3    In the upper right corner of the window:

 

Displays the customer address so the user can verify that the correct Sales Order is to be processed.

 

11.7.4    In the center of the window:

 

·         Displays a scrollable list of all open items in the Sales Order with the order quantity and the quantity that you want to issue. Items will not be included on the list if the Complete field on the Sales Order contains a "Y" or if the quantity previously issued against the item equals or exceeds the order quantity.

·         If the quantity to be issued exceeds the quantity available in the selected inventory area, an exclamation point "!" will appear to the right of the issue quantity number. See Item 0001 on the example picture on the previous page.

 

11.7.5    In the lower left of the window:

 

·         The Full Fill button will automatically set the issue quantities for all the items to equal the order quantities.

·         The Limit Fill button will automatically set the issue quantities to issue as much of the item as is available in the selected Inventory area, up to the order quantity.

·         The Zero All button will reset all issue quantities to zero.

·         The More Detail button is not used when issuing to shipping.

·         In the lower center of the window:

·         This section displays information about the item currently highlighted in the center section. It also displays the quantity of this item currently available in the selected Inventory area.

·         At the bottom of this area, you can manually set the issue quantity and enter a serial or lot number to be associated with this item. The serial/lot number will be retained as part of the Stock transaction record.

·         The Full, Limit, and Zero, buttons function just like the Full Fill, Limit Fill, and Zero All buttons but affect only the highlighted item.

·         The Item Detail button, like the More Detail button, is not used when issuing to shipping.

·         In the lower right corner of the window:

·         The OK button begins the issue process for the items you have specified while the Cancel button exits the screen without making any changes.

·         The Default button opens a second window where some of the behavioral characteristics can be set. 

 

11.7.6        The Default Settings window: (The initial default settings are shown.)

 

Stock Issue-Ship defaults

 

 

When a Sales Order is loaded into the first window for processing, the issue quantities for all items will be automatically entered based on the default Issue Quantities setting displayed in this window. The default Inventory issuing area can also be specified.

 

If the Update quantities when Area changes box is checked, changing the Inventory area on the first screen will automatically update the issue quantities based on the Issue Quantities setting.

 

If the Warn if over issuing against order box is checked, a warning message will appear before transaction processing begins if the issue quantity of any of the items exceeds the order quantity. You then have the option to continue with the over-issue condition or return to the window for further editing.

 

If the Warn if insufficient quantity in Area box is checked, a warning message will appear before transaction processing begins if the issue quantity of any of the items exceeds the quantity available in the selected Inventory area. You then have the option to continue with the over-issue condition (which will drive the Inventory quantity negative) or return to the window for further editing.

 

The Track Serial/Lot Numbers box will be activated for those users who have purchased the optional Serial/Lot Number module. When this box is selected, the Track SN/Lot check box on the first window will start in the checked condition.

 



 

11.8    B - Issue Transfer Parts Between Inventory Areas

 

 

This transaction allows users to transfer inventory parts and assemblies between inventory areas. You can rename the alternate storage areas using the configuration menu, option 34.  Transferring inventory from area 1 (Stores) into an alternate area creates an ISSTB record.  Transferring inventory from an alternate area into area 1 (Stores) creates a RECFB record.  Transferring inventory from an alternate storage area into another alternate storage area creates both an ISSTB and RECFB record.

 

11.9.1    R - Receive Completed Assemblies from Manufacturing

 

This module allows completed assemblies to be received from manufacturing back into the stock room. pc/MRP uses the following pseudo code when completed assemblies are returned from manufacturing to the stock room:

 

The above method allows overages and waste to be deducted from WIP. It also does not require all parts to be issued before part of the sales/work order is returned as finished assemblies.

 

pc/MRP will ask for the sales/work order number that you wish to turn in as completed assemblies. It will then locate the original sales/work order record to determine how many assemblies were originally ordered and issued. pc/MRP will ask for the quantity being received and then increment the onhand quantity of the assembly listed on the sales/work order. Next, it will search the stock transaction data base file and decrement the WIP quantities of all parts issued to manufacturing for that sales/work order. If you are turning in a partial order, it will make a partial deduction of the parts issued to manufacturing for that sales/work. For example, if you are turning in 6 completed assemblies for a sales/work order for 10 assemblies. pc/MRP would decrement the exact quantity of bolts, nuts, wheels, etc. for six assemblies.

 

With pc/MRP versions 8.10P and higher, creating a file named “AllowPartsIssRec.flg” with Notepad, will allow pc/MRP to receive back a Sales/Work Order line item that contains an inventory part instead of an assembly. Software Arts does not recommend using this option. It will remove from WIP all the parts issued to that Sales/Work Order line item and increase the quantity of the part listed on the Sales/Work order line item.

 

Please note:

·         In pc/MRP versions 7.73 and higher, when performing the R type transaction, users will be presented with the additional screen below:

 

11.9.2    Receive Back Completed Assemblies Shortage Warning

 



 

If pc/MRP determines that the work order or sales order you are receiving back can not be received back in full, it displays the following screen. 

 

 

This screen allows users to quickly determine the status of the build.  Users can see the quantity required, quantity already received from manufacturing, the quantity the user has requested returned back from manufacturing, and the calculated quantity that can be returned based on the material issued thus far.  Users can also view the shortage report for this build and print the shortage report.  If users choose to view the shortage report, once they are finished viewing the report, they will be returned to this status window.

 

After entering R type transaction pc/MRP will ask for the number of labor hours required to complete this assembly. With versions 7.73 and higher, you can populate the labor hours from the Employee Time Tracking module by setting option 79 within the Settings and Utilities menu.  The average labor cost entered into the transaction can be set to be derived from the employee pay rates or Option 6 from within the Settings and Utilities menu.  If you select the average labor cost to be derived from the employee pay rates, the following formula will be used:

 

SUM of different employees (employee pay rate * work hour + employee pay rate *

overtime * overtime pay rate factor)

total hours of employees

pc/MRP will display the next available stock transaction number. Press OK to accept the number.

If there is a sales or work order number for this transaction, enter Yes, and enter the sales order number. pc/MRP will use the Sales/Work Order Number to determine which and how many part(s) or assembly(s) should be received.

 

pc/MRP will ask if you wish to track Lot Numbers.

 

Enter the Quantity of assemblies or parts being returned from manufacturing. If the quantity of assemblies being turned in matches the quantity of assemblies originally issued to manufacturing, all of the items issued to manufacturing for the sales/work order number will be deducted from WIP. If a partial quantity of completed assemblies is turned in, pc/MRP reduces the quantity in WIP as described above.

 

The Onhand quantity of the assemblies or parts will increase in inventory.

 

The Quantity Assembled will be increased in the Sales/Work Order.

 

If it is for a Work Order, and the quantity assembled is equal to or greater than the original quantity required, a "Y" will be placed in the Complete Field.

 

 



 

11.10    U - Receive Unused Returned Parts from Manufacturing

This option allows users to return unused parts back into inventory. When users select this option, the choices above will appear. This selection screen allows users to enter the criteria for the jobs to be returned. The next screen will generate a list of all material allowing the user to choose which items and the quantity to be returned.



 

 

11.11    V - Receive Parts from Receiving

 

Enter a "V" to receive parts from receiving.  pc/MRP will display the next available stock transaction number. Press OK to accept the number.  If there is a receiver for this transaction, enter Yes, and enter the receiver number.  pc/MRP will ask if you wish to track Lot Numbers.  pc/MRP will display and receive each line item from the receiver. The onhand quantity of each part received will be increased provided pc/MRP is configured to do so in the configuration menu.

 

Do not use this transaction if you are set to Inventory Adjustment method A, see Settings and Utilities option 4.

 

11.12    A - Adjust Onhand Quantities

 

This option allows the onhand quantity of parts to be adjusted (increased or decreased). It leaves a record of the adjustment; where as editing the part number, would not leave a record of the adjustment. Increasing the onhand quantity in stores or in another area creates RECFA stock transaction record(s). Decreasing the onhand quantity in stores or in another area creates ISSFA stock transaction record(s). If you are utilizing the Serial Lot Number Module, this transaction will also automatically adjust quantities in the Serial Lot Number database.

 

11.13    T - Return all Parts/Assemblies Issued to a Sales/Work Order

 

This option allows users to un-issue sales or work orders from manufacturing.  This option subtracts the quantity issued into WIP for each part and or subassembly to a specific sales or work order and increments inventory in the issuing area.  Pc/MRP will prevent users from using this if they have already performed the R type transaction (qty assembled > 0).

 

11.14   S- Issue Parts or Assemblies to Shipping

 

This option was created for companies that do not use pc/MRP’s Invoice module. If you use this option, set the inventory Adjustment method, Option 4, to ‘S’.

 

Do not use this option if you are using pc/MRP’s Invoice module, as you will get a double decrement on your invoice movement report.

 

11.15    Scroll Inventory

 

Allows you to scroll or search for a part number. Select scroll if you know the first part of the part number, model number, or description. Select search if you wish to find the part by entering a partial description. For example, entering "elb" would reveal all of the parts, such as elbow, that have the letters "elb" anywhere in their description.  A more complete search feature is available in the Queried Search feature in the Inventory module.

 

11.16    Check Availability (Of Parts For A Specified Assembly)

 

Will print out the status (quantity on hand, quantity on order, and quantity required) for each part number in a specified assembly. pc/MRP will ask for the BOM number and the quantity required. Enter P to check for parts infinite levels deep or S for sub-assemblies and parts to one level deep. If any part is short, the report will list it as, "SHORT". This report is not as thorough as the Consolidation Report in Purchasing as it only looks at what is currently on hand. A narrow carriage print out will include a purchasing history of parts that are short. A wide carriage printout will include reference designators.

 

If you select Print and Parts Only, the Check Availability will include PO Status for each part number that is short.  

 

If you check ‘Factor in On Demand Qty’ for the Check Availability report, it may not agree with the On-Demand qty found in the inventory screen because the report’s on-demand qty subtracts the qty issued while the screen’s On-Demand does not.

 

11.17    Edit/View (Delete/Undelete A Stock Transaction)

 

This option allows users to scroll, edit, delete, undelete, or run queries on Stockroom 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, Document Number, Sales and Work order Number, Part Number, or Model Number

·         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 Stockroom table.  For further details, see chapter 15.14.

 

Every field in the Stockroom table is editable.  Users however need to understand several key concepts before editing stockroom records.

·         There are three key fields in most stockroom transaction, REQUIRED QTY, ISSUED QTY, and RETURNED QTY.  The REQUIRED QTY is the quantity required for this transaction.  ISSUED QTY is the quantity actually issued for this transaction.  If applicable to the transaction there may also be the RETURNED QTY, this is the quantity returned or backflushed for this transaction. 

·         When the REQUIRED QTY does not equal the ISSUED QTY, pc/MRP will flag this as a shortage in the stockroom shortage report.  To correct a shortage where none exists, the job is already complete and returned from manufacturing; users must research to see what has happened.  When performing the R type transaction pc/MRP will not warn users if a shortage still exists.  Thus, in some instances, can make inventory be incorrect by not fulfilling makeup shortage transactions before the R type transaction.  Users must research to see if the shortage needed to be fulfilled or if the job was completed with the shortage. 

·         If the shortage needs to be fulfilled, edit the ISSUED QTY to equal the REQUIRED QTY and manually deduct the difference from inventory.

·         If the shortage does not need to be fulfilled, edit the REQUIRED QTY to equal the ISSUED QTY.

·         There is a key of TRANSACTION TYPES in the edit screen of each stockroom transaction.

·         Use the delete and undelete buttons to mark and unmark records for deletion.  Once the record has been marked for deletion, return to the menu and select REMOVE ALL DELETED RECORDS FROM DISK AND REINDEX.  Removing stockroom transactions will not automatically change inventory.  It is not recommended to delete stockroom transactions.  If users choose to delete stockroom transactions and they wish to adjust inventory, they must manually accomplish each task.

 

11.18    Reports (Printout/Display Stock Transaction Reports)

 

Selecting Modules, Stockroom, Reports will display the screen shown below.

 



The above screen will allow you to display/print all manner of stockroom reports.

 

11.19    Convert Parts To Assemblies

 

Provides a short cut method that automatically converts parts into assemblies. This routine bypasses putting parts into WIP and using a work order number to record the transactions. If you select the print out option, you will receive a printed record of the transaction that can double as a PICK list. If any of the parts are short, pc/MRP will stop and ask how parts you wish to issue? If you issue the full amount, the onhand quantity in inventory will go negative. 

 

pc/MRP versions 8.01 and higher will create records of these transactions. Without these transaction records, the Inventory Movement report will not be accurate.  pc/MRP versions 7.92G and higher will disable this option if a file named ‘NOCONVERTPARTSTOASSY.FLG’ exists in the pcmrpw directory.

 

11.20    Index

 

Re-indexes the Stock Transaction 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 stock transaction record, re-indexing the index file is usually the cure.

 

 

11.21    Remove Marked Records

 

Removes all stock transaction records marked for deletion from the disk. The records will no longer be recoverable.

 

 

11.22    Remove Over X Years

 

Deletes and removes from the disk all Stock Transactions over a specified number of years old. Prior to running this command, it is advisable to save the Stock Transaction Database File (stocktra.dbf) to disk and label it "Stock Transactions DBF as of MM-DD-YYYY". You should also generate a printout of the file prior to closing it out.

 

 

11.23  Special Cases - Issuing Reels

 

Reels containing thousands of electronic components that must be issued to an assembly vendor or the manufacturing floor present a special issuing and tracking problem, as you must issue more than the quantity required to the machine picking off the required number of components. This can be resolved in one of the following ways:

 

 

11.24.1  Handling Scrap Parts

 

You have used the Stockroom’s ‘I’ Transaction Type to issue all the parts for 200 bicycles for a sale or work order.   Part of the issue included 200 inner tubes.   Two of the inner tubes are defective.  

 

Use the Stockroom’s ‘L’ Transaction Type to issue two more inner tubes to the sales or work order. 

OR

Use the Stockroom’s ‘U’ Transaction Type to return the two defective inner tubes to an area designated as scrap.  Select ‘Reduce the Quantity Issued’ but not the ‘Quantity Required’.    Use the Stockroom’s ‘P’ Transaction Type to issue two more inner tubes when they become available.

 

Once the bicycles are built, use the Stockroom’s ‘R’ Transaction Type to receive back the 200 completed bicycles.

 

Please note that pc/MRP’s Serial/Lot Number module will record the serial numbers for ‘I’, ‘R’, ‘A’, ‘U’, and ‘L’ the stockroom transactions.

 

11.24.2  Reporting Inventory Scrap transactions

 

Stockroom 'B' transactions allow transfer of parts from one stores area to another stores area.

Transferring from Stores area 1 to another area only creates an 'ISSTB' stockroom transaction, whereas transferring from say R&D stores area to 'Scrap' stores area will create both an ISSTB' and a 'RECFB' record.

 

Now, if you wish to track all transactions affecting the 'Scrap' stores area, you could enter the word 'Scrap' in the 'Rel Doc No' data field in the Stockroom 'B' type transaction and then run the Stockroom, 'All for a Related Document Number', and enter 'Scrap' in the 'Related Document #' data field. Select 'Partial' for the 'Match Type' (this means Starts With...), and then select for Include, 'All Stock Transactions'. For just a partnumber of group of product codes, append the partnumber product code to the word 'Scrap' when entering into the 'Rel Doc No' data field of the stockroom transaction and the report's 'All for a Related Document Number' data field.

 

Other Stockroom transaction types will require you to edit the transaction after entry so you can enter the 'Rel Doc No' data.

 

11.25   Handling Finished Assembly Yields

 

You have used the Stockroom’s ‘I’ Transaction Type to issue all the parts for 200 circuit boards for a sale or work order.

 

Use the Stockroom’s ‘R’ Transaction Type to receive back the 200 completed circuit boards into a stores area.

 

Inspection rejects five of the finished circuit boards ‘A’ (This must occur after the Stockroom’s ‘R’ Transaction Type).

 

Use the Stockroom’s ‘B’ Transaction Type to move the 5 finished/rejected Circuit Boards from a stores area to a scrap area. At the end of the financial period, print out an inventory value report for the scrap area (cuspar01-11). Make an accounting adjusting entry for the value of the scrap; credit Inventory asset and debit a COG type account.

OR

Use the Stockroom’ ‘A’ Transaction Type to decrement the quantity in the stores area by 5.

 

Please note that pc/MRP’s Inspection Module provides a record of the inspection, and the quantity rejected but does not adjust any on hand quantities.

 

Accounting should be notified of any ‘A’ type adjustments to inventory so they can adjust their inventory asset and COG account values.