Receiving By-products On Shop Orders—Extended Exercises

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. If you haven't done so already, 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 locations shown in the table below.

General exercise for Entering Inventory Locations

Default Inventory Location for Part

Purpose: The purpose of this exercise is to set up default inventory locations for parts that are received automatically.

Windows:
Inventory Parts/Default Locations

1. If you haven't done so already, define the default inventory locations for the parts in the table below.

General exercise for Manufactured Inventory Part

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 shop orders to be used in the main exercises below.

Prerequisites: Handling By-products on Shop Orders exercise.

Windows:
Shop Order

Note: This exercise continues processing the shop orders created in the prerequisite exercise.

1. Verify that you have shop orders for the parts and quantities below. These shop orders should be in either a Planned or Released state. Record the shop order numbers in the Shop Order Number column.

Main Exercises

Purpose: The purpose of these exercises is to receive by-products on shop orders using both automatic and manual processes.

Windows:
Inventory Part Currently On Hand
Shop Order
Shop Order/By-Product
Shop Order/Detail

The oil pan for the racing engine is a manufactured part that is produced from sheet steel with a by-product of scrap steel. Rarely, steel disks are stamped from the sheet steel along with the oil pans. The following shop orders exist:

• A shop order for 20 oil pans and the standard by-product of scrap steel. You want to receive the oil pans and scrap steel as defined on the shop order.
• A shop order for 20 oil pans with steel disks and the scrap steel as by-products. You want to receive the steel disks and the scrap steel manually because the actual amount produced may vary from the definition on the shop order.

Automatically Receiving By-products with Shop Order Product

For the shop order for 20 oil pans and the standard by-product of scrap steel, you want to receive the oil pans and scrap steel as defined on the shop order.

1. Open the Inventory Part Currently On Hand window. Query for the parts in the table below and record the total quantity available.

2. 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 20. Verify on the Byproduct tab that the 21-935 part is the only by-product and that it has a lot size of 10.
3. If the shop order is in a Planned state, release the shop order.
4. Issue all of the material and report the time on the operations.
5. Right-click anywhere in the header, point to Material Actions, and then click Receive. 
6. Click Yes to confirm that you want to receive all remaining material on the shop order.
7. Click the Detail tab and verify that the value of the Qty Complete field is 20, which represents the receipt of oil pans.
8. Click the Byproduct tab and verify that the value of the Qty Complete field is 10, which represents the receipt of scrap steel.
9. In the Inventory Part Currently On Hand window, query again for your site and part numbers 21-313 and 21-935. Verify that the quantity available for the two parts has increased by the quantity received.

Manually Receiving By-products on a Shop Order

For the shop order for 20 oil pans with steel disks and the scrap steel as by-products, you want to receive the steel disks and the scrap steel manually because the actual amount produced may vary from the definition on the shop order.

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 20. Verify on the Byproduct tab that there are two by-products, part numbers 21-935 and 21-936.
2. If the shop order is in a Planned state, release the shop order.

Note: It is not necessary to issue the material or report the time on the operations before receiving by-products.

3. Right-click anywhere in the header, point to Material Actions, and then click Manual Receive.
4. In the Received Part area on the Receive Shop Order window, verify that the first field has Shop Order selected, the Remaining Qty field has a value of 20, and the other two fields show part number 21-313 and Oil Pan. These fields represent the part to be received. 
5. In the first field in the Received Part area, pull down the list and click Byproduct (instead of Shop Order). Verify that the values of the other fields in the Received Part area have changed.
6. Click in the part number field in the Received Part area, and then open the List of Values to see the defined by-products on this shop order. Select part number 21-936 to receive the steel disks. If you receive a message that indicates that the part does not have a manufacturing revision in effect, click OK.
7. If no location records display in the table on the Inventory Receipt tab, create a new record. Enter 80 in the Quantity Received field and 2C in the Location No field. If a record is displayed in the table, enter 80 in the Quantity Received field for the displayed record. Save the information.
8. In the first field in the Received Part area, pull down the list and click Byproduct. Click in the part number field in the Received Part area, and enter 21-935 to receive the scrap steel. If you receive a message indicating that the part does not have a manufacturing revision in effect, click OK.
9. If no location records display in the table on the Inventory Receipt tab, create a new record. Enter 5.5 in the Quantity Received field and 2C in the Location No field. If a record displays in the table, enter 5.5 in the Quantity Received field for the existing record. While the value of the Remaining Qty field is 6, only 5.5 was produced. Save the information.
10. In the first field in the Received Part area, pull down the list and click Shop Order. Verify that 21-313 is the value in the part number field in the Received Part area and that the Remaining Qty field value is 20.
11. Select the Receive With Backflush check box to issue the material. Select the Auto Report Of Operations check box to report the time.
12. If no location records display in the table on the Inventory Receipt tab, create a new record. Enter 20 in the Quantity Received field and 2C in the Location No field. If a record displays in the table, enter 20 in the Quantity Received field for that existing record. Save the information.
13. Close the Receive Shop Order window.
14. Click the Byproduct tab and verify that the value of the Qty Complete field is 5.5 for the 21-935 (Scrap Steel) part and 80 for the 21-936 (Disk, Steel, 5 cm) part. These values represent the receipt of the by-products.
15. On the row for the 21-935 part, change the value of the Lot Size field to 5.5 to prevent the receipt of additional scrap steel. Save the information.
16. Click the Detail tab and verify that the value of the Qty Complete field is 20, which represents the receipt of the oil pans. (It may be necessary to refresh the window.)
17. Right-click anywhere in the header, and then click Close to close the shop order. Click OK in the Close Shop Order dialog box.

Note: You can receive the by-product before or after the production part, but if a by-product is defined on the shop order, the shop order will not automatically close during the receipt process unless both the production part and the by-product has been completely received.