Once the components for a shop order have been pulled, the components are assembled into the top level part. When the top level part has been physically assembled or completed, the Shop Order Completion program is used to close the shop order and add the assembled item back into inventory.
Please Note: The Shop Order System will only allow you to complete a shop order when all components for the shop order have been pulled. This limitation allows the system to correctly process the inventory and cost updates that are required when a shop order is completed, and it simplifies the logic in the completion program. If you need to complete a shop order that has not been completely pulled or that is not completely allocated to, you should use the split option that is described later in this document.
The Shop Order Completion program actually performs several different functions which include.
• Calculating the cost of the item just completed and averaging this cost back into the inventory items that are included in the same division where the shop order is being completed.
• Updating the status of the shop order header and line items to show the order as completed or closed.
• Checking the serialized inventory flags for the top level items and the components in the shop order. If the top level or component items are serialized, the program prompts the operator to enter serial numbers as appropriate and or it automatically assigns a serial number to each of the top level items.
• Allocating the completed item. The completion program checks if the shop order was created for a specific sales order. If so the program allocates the completed item to the indicated sales order. If the shop order is not for a specific sales order, the completion program calls a program to allocate the new item to any sales or shop orders that are waiting for the item (the allocation program will not allocate to any shop or sales order lines that are flagged as printed when the allocation program is executed).
The following procedure can be used to complete a shop order in the Shop Order program.
1. Verify that the shop order to be completed has a pulled quantity equal to the shop order quantity (the quantity being built). You may only complete shop orders that have been completely pulled. If you need to complete less than the total quantity in the shop order you should use the split option that is described later in this document.
2. Select or highlight the shop order to be completed.
3. Use the Complete option (Ctrl+C) to complete the shop order. When you select this option, the system will prompt you with the bin that should be used for the top level item being completed, and the bin that should be used for any by-products or components that are returned to inventory at the end of the assembly process. The system will use a default bin for each of these items but you can override the default bin as required if necessary. Normally the default bin values are used and then the Bin Transfer program is used to move the items to the appropriate location in the warehouse at a later time (i.e. when the goods are actually physically moved to the new bin).
4. Once you have entered the Bin information, the completion program can be configured to automatically print a Shop Order Return to Stock Ticket (you can also configure the program to prompt you or to skip printing of the document). The Shop Order Return to Stock ticket lists the item and quantity that was built using the shop order and the bin that the completed item should be put away in. The document also lists any byproducts or components that need to be returned to stock and the bin that they should be put away in. The document will also print information about the sales order associated with the shop order (if applicable). This information includes the customer and order number and line from the shop order header.
5. The system then allocates the new top level item quantity. The system will first try to allocate the quantity just completed to the specific order and line specified in the shop order header. If no sales order line was specified in the Shop Order Header, the system allocates to the sales and shop order lines that are waiting for the item.