Once all of the components for a shop order have been pulled and the pull tickets have been processed, the item is physically assembled into the top level item. Once the item is assembled, the Complete Shop Order process is used to tell the system that the part has been built.
When a Shop Order is selected and the Complete Option is selected, the system first checks the pulled quantity for the shop order. If the shop order pulled quantity does not match the total quantity for the shop order, the system will not allow you to complete the order. The system requires you to complete the entire shop order quantity at one time to ensure that the top and component level costs and quantities are updated correctly. This logic makes the completion program more straightforward and it prevents errors due to changing the component mix for the item being built during the build process.
If you need to complete a partial quantity for a shop order due to a shortage of components, the split option can be used to split the shop order into two different shop orders. The Split option allows the operator to move the appropriate pulled and allocated quantities from the original order to an order that is fully allocated and or pulled. This allows the partial quantity that you do have components for to be completed. The remaining shop order quantity is then left in the system until the missing components can be allocated and pulled. It is completed at a later time.
As each shop order is completed, the system.
• Updates the shop order header and line status.
• Updates the top level quantity of the item just built.
• Updates the average weighted cost of the item just built. The cost of any stocking components, any nonstock components like labor or consumables is included in the top level cost. These items are “consumed” or added to the top level item cost only when the item is completed.
• Returns any component items that were byproducts (extra parts produced by the assembly process) to inventory.
• Attempts to allocate to any sales order line that was specified in the shop order. If a sales order line is specified in the shop order, the system will allocate the inventory item just built to the order unless there is a Pick Ticket currently printed for it (the system does not allocate to order lines that are printed and in the process of being picked).
• Prints a Shop Order Processing Return to Stock Ticket. The Return to Stock Ticket lists the item just built, it identifies the sales orders that the item was built for (if appropriate) and it lists any byproducts or components that should be put back into inventory as a result of the shop order completion.