This procedure is used to enter a new shop order into the system.
1. Verify that the components and the item to be built exist in the Inventory Location in which you are processing shop orders, and that a Bill of Materials has been set up for the item to be assembled.
2. Select the Shop Order Management program from the Shop Floor Menu. The Shop Order Management program is used to create, edit and process the Shop Orders on your system.
3. Use the Insert option to create a new shop order. When you press the Insert Key or Button, the system displays the Bill of Materials Lookup program. The Bill of Materials Lookup program displays the Bills of Material that have been defined on your system. The Lookup program contains status checkbox and type selections that allow you to filter the Bills of Materials that are displayed. You may need to change these selections based on the status and type of the BOM to be used for the new Shop order.
4. Enter the quantity to be assembled. As you enter the shop order, the system will prompt you to select the appropriate BOM record and it will then prompt you to enter the quantity to be built and to fill in the other required fields in the Shop Order Header. Save the Shop Order using the Save key. As the Shop Order is saved, the system will automatically create shop order lines based on the selected BOM and it will display the line items in the Shop Order Lines program. Each of the shop order lines will automatically be loaded with the correct quantities based on the BOM being processed and the number of top level items being built. At this point you can modify the components for the current shop order if necessary. This will not change the BOM for the shop order, only the components for the shop order being processed.
5. Once the component detail for the shop order is displayed, you can view the quantities and the status of each shop order line item. The quantities shown in the Shop Order Lines program include the following
• Qty: The quantity from the BOM (the quantity of each component required to build 1 top level item)
• Extended quantity (the total quantity of the component required for the current shop order).
• Allocated: The Allocated quantity indicates the quantity of the component item that has been automatically allocated or assigned to the shop order. You may not pull the inventory for a shop order until the inventory has been allocated to the order. There is also an allocated quantity that is maintained in each shop order header. That number is used to tell you the number of top level parts that can be built based on the allocation quantities for each component (if you are building a quantity of 5 top items but only have enough components allocated to build 3 completely, the shop order header would show 3 in the allocated field).
• Pulled: The Pulled field indicates the quantity of the required component that has already been pulled into work in process (the production area) for the selected shop order. The pulled quantity is updated each time you process a pull ticket to pull components from inventory and move them to work in process. The system also maintains a pulled quantity in the shop order header. The pulled quantity in the header is used to tell you the number of top level parts that components have been completely pulled for. You may not complete a shop order until the pulled quantity in the header is the same as the quantity to be built.
6. Once the shop order lines have been verified or changed, you can finish saving the new shop order by pressing the Save Key. At this point the system can be configured to prompt you to print a document for the shop order. You may print a document at this point by selecting the appropriate option or you can press escape if you do not wish to print a document.