Closing Shop Orders—Extended Exercises

Basic Data Setup

Discrete Manufacturing Overview Racing Engine

Purpose: The purpose of this exercise is to create the required data that will be used in the Discrete Manufacturing exercises. This sets up data for your site that only needs to be done once for Discrete Manufacturing course exercises.

1. Set up your site for discrete manufacturing of racing engines.

General exercise for Overview of Discrete Manufacturing Data

Inventory Location

Purpose: The purpose of this exercise is to set up an inventory picking location for running functionality isolated by site.

Windows:
Inventory Locations

1. If you haven't done so already, create the inventory picking location shown in the table below.

General exercise for Entering Inventory Locations

Required Data

Inventory Part Balance

Purpose: The purpose of this exercise is to verify that you have enough parts to complete the main exercises. 

Windows:
Inventory Part Currently On Hand
Receive Inventory Part

1. Verify that you have at least the quantity of parts shown on the table below available for manufacturing. If you do not, receive the indicated quantity of the parts into inventory picking locations.

General exercise for Receiving Inventory Part

Shop Orders

Purpose: The purpose of this exercise is to create the shop orders that will be used in the main exercises below

Note: These shop orders will need to be processed to specific states for the exercises.

1. Create shop orders for the parts and quantities shown in the table below.
2. Record the shop order numbers so that it will be easy to identify the correct shop order for each main exercise.

General exercise for Creating Shop Orders Manually

Main Exercises

Purpose: The purpose of these exercises is to close shop orders by closing them manually and closing them with the auto-close process.

Windows:
Shop Order

There is one shop order for electrical systems and one shop order for oil pans. You want to:

• Set the close tolerance to 10% for a shop order for 10 electrical systems. You want the shop order to close automatically when the receipt of material is within the close tolerance.

Receiving and Automatically Closing a Shop Order

You want to set the close tolerance to 10% for a shop order for 10 electrical systems. You want the shop order to close automatically when the receipt of material is within the close tolerance.

1. Open the Shop Order window and query for the shop order for this exercise. If you did not record the shop order number, query for your site, part number 21-230 and a quantity of 10. If the shop order is not released, release it.
2. Right-click anywhere in the header, point to Material Actions, and then click Reserve to reserve the material for your shop order.
3. Click the Detail tab. Verify the value in the Tolerance field (in the Auto Close area). Also verify that Auto Close is selected from the Code list.

Note: If you have specified a value in the Close Tolerance field of the Inventory Part/Manufacturing tab, it will be displayed in the Tolerance field of the relevant shop orderby default.

4. Change the Tolerance field value to 10. This will allow the shop order to automatically close if it receives at least 9 electrical systems (10 - 1).
5. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive.
6. When the Receive Shop Order window displays, select the Receive With Backflush check box. Also select the Auto Report Of Operations check box.
7. On the Inventory Receipt tab (in the Receive Shop Order window), check for a record for location 2C. If a record for location 2C does not appear, create a new record, entering 2C in the Location No field. If there is already such a record, use it.
8. In the Quantity Received field, enter 8.
9. Save the information.
10. Close the Receive Shop Order window.
11. Refresh the Shop Order window.
12. Verify that the state in the header has changed to Started.
13. On the Detail tab, verify that the Qty Complete field now displays 8 and that the value in the Products field has changed to Partially Received. In the State area, verify that the value of the Material field is Partially Issued, and the value of the Operations field is Partially Reported. The shop order did not close automatically because the material reported complete was not within the close tolerance.
14. Right-click anywhere in the header, point to Material Actions, and click Manual Receive.
15. When the Receive Shop Order window displays, select the Receive With Backflush check box. Also select the Auto Report Of Operations check box.
16. On the Inventory Receipt tab (in the Receive Shop Order window), enter 1 in the Quantity Received field.
17. Save the information.
18. Close the Receive Shop Order window.
19. Refresh the Shop Order window.
20. Verify that the state in the header has changed to Closed.
21. On the Detail tab, verify that the Qty Complete field now displays 9 and that the value in the Products field has changed to Partially Received. In the State area, verify that the value of the Material field is Completely Issued, and the value of the Operations field is Completely Reported. The shop order closed automatically because the material reported complete was within the close tolerance.
22. You decide that you want to reopen the shop order and receive the last electrical system. Right-click anywhere in the header, and then click Open. Verify that the state in the header has changed to Started.
23. Click the Material tab. Verify that the value in the Qty Required field for each row had changed to 9 when the shop order was automatically closed. Change the value to 10 in the Qty Required field for each row. Save the information.
24. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive.
25. When the Receive Shop Order window displays, select both the Receive With Backflush check box and the Auto Report Of Operations check box.
26. On the Inventory Receipt tab (in the Receive Shop Order window), enter 1 in the Quantity Received field.
27. Save the information.
28. Close the Receive Shop Order window.
29. Refresh the Shop Order window.
30. Verify that the state in the header has changed to Closed.
31. On the Detail tab, verify that the Qty Complete field now displays 10 and that the value in the Products field has changed to Completely Received. In the State area, verify that the value of the Material field is Completely Issued, and the value of the Operations field is Completely Reported. The shop order closed automatically because the material reported complete was within the close tolerance.
32. Close the Shop Order window.

Receiving and Manually Closing a Shop Order

You want to set the close tolerance to 10% for a shop order for 10 oil pans. You also decide that you want to close the shop order manually after 11 oil pans have been received.

1. Open the Shop Order window and query for the shop order for this exercise. If you did not record the shop order number, query for your site, part number 21-313 and a quantity of 10. If the shop order is not released, release it.
2. Right-click anywhere in the header, point to Material Actions, and then click Reserve to reserve the material for your shop order.
3. Click the Detail tab. Verify that the value in the Tolerance field (in the Auto Close area) is 0. Verify that Auto Close is selected from the Code list.
4. Change the Tolerance field value to 10. This would allow the shop order to automatically close if it received at least 9 electrical systems (10 - 1).
5. In the Code list in the Auto Close area, click Manually Close so that the shop order will not close automatically when the close tolerance has been satisfied.
6. Save the information.
7. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive.
8. When the Receive Shop Order window displays, select both the Receive With Backflush check box and the Auto Report Of Operations check box.
9. On the Inventory Receipt tab (in the Receive Shop Order window), check for a record for location 2C. If a record for location 2C does not appear, create a new record, entering 2C in the Location No field. If there is already such a record, use it.
10. In the Quantity Received field, enter 8.
11. Save the information.
12. Close the Receive Shop Order window.
13. Refresh the Shop Order window.
14. Verify that the state in the header has changed to Started.
15. On the Detail tab, verify that the Qty Complete field now displays 8 and that the value in the Products field has changed to Partially Received.
16. Right-click anywhere in the header, and then click Close. When the Close Shop Order window displays, click OK without changing the values in any fields.
17. Click OK to acknowledge the message that the shop order cannot close because the product is not within the close tolerance.
18. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive.
19. When the Receive Shop Order window displays, select both the Receive With Backflush check box and the Auto Report Of Operations check box.
20. On the Inventory Receipt tab (in the Receive Shop Order window), enter 1 in the Quantity Received field.
21. Save the information.
22. Close the Receive Shop Order window.
23. Refresh the Shop Order window.
24. Verify that the state in the header is still Started.
25. On the Detail tab, verify that the Qty Complete field now displays 9 and that the value in the Products field has is still Partially Received.
26. Right-click anywhere in the header, and then click Close. When the Close Shop Order window displays, click OK without changing the values in any fields.
27. Click OK to acknowledge the message that the shop order cannot close because the product is not within the close tolerance. This is because none of the by-products has been received.
28. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive.
29. When the Receive Shop Order window displays, in the Received Part area, verify that the list displays Shop Order, the Remaining Qty field has the value 1 and the other two fields show part number 21-313 and Oil Pan. These fields represent the part to be received. In the list, click Byproduct. Verify that the values of the other fields in the Received Part area change to the information for part 21-935 (Steel, Scrap).
30. On the Inventory Receipt tab (in the Receive Shop Order window), check for a record for location 2C. If a record for location 2C does not appear, create a new record, entering 2C in the Location No field. If there is already such a record, use it.
31. In the Quantity Received field, enter 4.5.
32. Save the information.
33. In the list under Received Part (of the Receive Shop Order window), click Shop Order. Verify that the other field values in the Received Part area change to the information for the 21-313 (Oil Pan) part.
34. Select both the Receive With Backflush check box and the Auto Report Of Operations check box.
35. In the Quantity Received field in the table, enter 2 to receive the last of the 11 oil pans.
36. Save the information.
37. Click Yes to indicate that you want to continue after receiving the system warning that you are receiving more material than was originally ordered and that you would need to manually issue any additional component material needed in excess of the quantities allocated for the shop order lot size. You will not need to manually issue additional material.
38. Close the Receive Shop Order window.
39. On the Detail tab, verify that the Qty Complete field now displays 11 and that the value in the Products field has changed to Completely Received.
40. Right-click anywhere in the header, and click Close. Verify that the state of the shop order has changed to Closed. The shop order was able to close because both the material and the by-product quantities that were reported complete are within the close tolerance.
41. Close the Shop Order window.

Manually/Automatically Receiving More Than The Shop Order Lot Size.

Windows:
Receive Shop Orders

If you want to receive more than the planned lot size.

1. Open the Shop Order window and query for the desired shop order number.
2. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive.
3. When the Receive Shop Order window displays, select the Backflush check box and the Auto Report Of Operations check box, in the Material and Operations area.
4. On the Inventory Receipt tab (in the Receive Shop Order window), in the Quantity Received field enter a quantity bigger than the planned lot size.
5. When you try to save it, a warning message will be displayed informing you about the excess quantity. If you wish to continue click Yes, else click No.
6. The received total quantity will now be in the selected inventory location.